7FBR RM Vol1 CE351

foreword_E_vol1.
fm 1 ページ２０１２年７月９日月曜日午前７時２７分
FOREWORD
This Manual (Volume 1) contains maintenance, specifications and repair pro-
cedure for the chassis, body and material handling system of the TOYOTA
ELECTRICAL POWERED FORKLIFT 7FBR10 to 18 series.
For electrical wiring diagrams, diagnosis and service procedures of electrical

controller and display, please refer to Volume 2 (Pub. No. CE352) issued
simultaneously.
Please use these manuals for providing quick, correct servicing of the corre-
sponding forklift models.
This manual deals with the above models as of July, 2012. Please under-
stand that disagreement can take place between the descriptions in the man-
ual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18

REPAIR MANUAL VOL.2 (Pub. No. CE352)
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
sec_index_E_vol1.fm 1 ページ２０１２年７月１０日火曜日午後３時３７分
SECTION INDEX
NAME SECTION
INSTRUCTION MANUAL NMF

GENERAL 0
BATTERY 1
CHARGER 2
CONTROLLER 3
DISPLAY 4
TROUBLESHOOTING 5
MOTOR 6
DRIVE UNIT 7
SUSPENSION & CASTER WHEEL 8
STEERING 9
FRONT BRAKE & AXLE 10
REAR BRAKE 11
BODY 12
MATERIAL HANDLING SYSTEM 13
MAST 14
CYLINDER 15
OIL PUMP 16
OIL CONTROL VALVE 17
HYDRAULIC PIPING 18
TBC•EPS 19
APPENDIX 20
ELECTRIC WIRING DIAGRAM 21
Section indicated by solid characters are included in this manual.
Section indicated by half-tone characters: Refer to vol. 2 (Pub. No. CE352).
X630_NMF_description_A4.book 1 ページ２０１２年７月９日月曜日午前１０時３２分
NMF-1
NEW MODEL FEATURES
Page NMF
AIM OF DEVELOPMENT .................................. NMF-2
0
MAIN SELLING POINTS................................... NMF-3
1
MAIN DIFFERENCES
FROM PREVIOUS MODELS ......................... NMF-6 2
BATTERY .......................................................... NMF-7 3
ON-VEHICLE CHARGER ................................. NMF-20
4
DRIVE MOTOR.................................................. NMF-27
5
PUMP MOTOR .................................................. NMF-28
BASIC FUNCTION ............................................ NMF-33 6
DRIVE UNIT ...................................................... NMF-42 7
MULTI FUNCTION DISPLAY DX ...................... NMF-43 8
PIN CODE ENTRY SYSTEM............................. NMF-92 9
10
11
12
13
14
15
16
17
18
19
20
21
NMF-2
AIM OF DEVELOPMENT
Product Development
Even in the midst of the economic downturn following the collapse of Lehman Brothers in September
2008, the key market for indoor products, represented by the reach-type forklifts used in the shipping,
warehousing and foodstuffs industries, is becoming stronger. However, following the entry of competing
brands of indoor products into the market in 2005 and the heightened competition as a result, Toyota's
lead over other brands in terms of domestic market share is tending to diminish.
Reflecting opinions expressed by users in 2008, Toyota has worked to provide a complete equipment
range, and currently holds that as a priority. However, to maintain its No.1 ranking in the domestic market
share and increase its lead over its competitors into the future, Toyota has also worked on the key
performance attributes of its electric forklifts, including reducing their power consumption and noise
levels as well as improving their durability.
1. Reduced consumption of electric power
We have introduced newly developed technology, including new AC motors and new motor drivers
that will reduce power consumption by reducing electrical loss.
We have also aimed to increase operator awareness of energy savings by installing the Multifunction
display DX, which includes functions that display power consumption.
The following energy-saving technologies have been adopted this time.
• Adopting the AC pump motor
• Adopting the new coil winding method on the drive pump motor
• Using low-loss elements in the motor driver for the drive pump
• Providing a power meter in the multifunction display DX that shows the consumed and
regenerated power levels
• Providing an optional integrating wattmeter in the multifunction display DX that shows daily and
monthly power consumption
• Using low rolling resistance bearings in the drive unit
2. Improved Noise reduction and durability
We have also improved durability and reduced noise levels by introducing new features such as
lower rotation rates in the drive unit, improved gear meshing and a battery protection function.
• Lower gear rotation rates in the drive unit and improved gear meshing
• Installing a battery electrolyte temperature sensor and adding battery electrolyte level/temperature
warnings and performance limitation functions to the multifunction display DX
(Installed as options on some models)
• Improved battery management through the provision of a rest-day equalized charging function
• Providing ribs on the rear door to reduce instrument panel deformation during collisions
In addition to the above, we have also improved operability by incorporating advanced functions
offered in other Toyota models.
• Inclusion of a wheel indicator as standard
• Enhanced management functions through the use of PIN code entry system and the addition of a
tuning memory function for each operator (optional)
• An improved anti-rollback function for easier operation on slopes
Along with the SAS-R, which has attracted the praise of many users since it was first released, and
following the expansion of the equipment range in 2008 and the latest improvements in basic
performance, we are confident that the enormous superiority of the GENEO-R over its competitors will
make it a formidable weapon in our efforts to further dominate the key market of the shipping,
warehousing and foodstuffs industries.
NMF-3
MAIN SELLING POINTS

Product Development
In the 7FBR10-18, the drive system and electrical units have undergone a complete makeover, resulting
in major improvements to the product. The table below lists the key selling points in these product
improvements and the items implemented.
z: Newly adopted item {: Improved item
NMF
Concept Functions Features Overview
Applicable
model
Remarks 0
Drive unit
The gear ratio of the drive unit has been
All models { 1
Excellent changed to improve the gear durability.
durability
Rear door
A rib has been added to the rear door to
All models { 2
improve the durability.
Extended operating
Due to the following improvements, the 3
operating time has been extended by All models {
time
10% of that of the previous models. 4
A new coil winding method has been
New AC drive motor All models
adopted to increase energy efficiency.
{
5
A DC motor has been provided instead of
New AC pump motor
an AC motor, and a new coil winding
All models z
6
Improved method has been adopted to increase
energy energy efficiency. 7
efficiency A new model high-efficiency inverter has
been provided exclusively for the drive 8
motor and the pump motor, and the travel-
New AC drive system All models z
ing control and the load handling control 9
have been integrated by the main control-
ler. 10
Low rolling resistance bearings have
Drive unit All models {
been used to increase drive unit efficiency 11
Battery electrolyte If a lack of battery electrolyte is detected,
level warning the battery electrolyte level warning
z 12
indicator indicator on the display lights. Also, when All models
*1
(Multifunction the key switch is turned off, it blinks to 13
display DX) increase the operator’s awareness.
If the battery is used with not enough bat- 14
tery electrolyte or heated battery electro-
Battery protection
function
lyte, a warning indicator lights, a buzzer
sounds, and the vehicle performance is
Option
z 15
*1,*2
Extended
battery life
limited in order to reduce damage to the
battery.
16
The monthly charging power is recorded
and displayed every 3 months, while the
17
daily integrated charging power is
recorded and displayed for each 30-day z 18
Integrating wattmeter Option
period. Once the basic unit for CO2 emis- *1,*2,*3
sions is set, the CO2 emissions for the 19
energy used are displayed, thereby
assisting with energy management 20
21
NMF-4
z: Newly adopted item {: Improved item

Applicable
Concept Functions Features Overview Remarks
model
If the accelerator is released on a slope,
this function limits the slope descending
Improved speed to a certain value to prevent the
Anti-rollback All models z
operability vehicle from creeping down. By this
function, operability and controllability on
a slope has been drastically improved.
The gear ratio of the drive unit has been
Noise reduction at changed to reduce the noise at traveling
All models {
traveling to a level same with the main competing
makers.
LED warning indicators and a full-dot
matrix LCD display have been adopted to
display various information in an easy-to-
Multifunction
see way according to the vehicle state All models z
display DX
and operation state. A wheel indicator and
Others
a load meter have been provided as stan-
dard.
Level meters display the energy supplied
from the battery to the motor along with
the regenerated energy supplied to the
Power meter battery during motor regeneration. This All models z
allows the operator to monitor the energy
consumption in real time and assists with
ecologically responsible vehicle operation
Equalized charging, which takes longer
than normal charging, is now controlled
Except for
so that it is carried out during rest days.
models
Down-time This ensures that there is ample time for z
without
equalized charging battery charging and for the battery to *3
on-vehicle
cool down after charging, thereby lessen-
charger
Others ing the impact of battery overheating on
operation days
A system in which a registered PIN (Per-
sonal Identification Number) code has to
PIN code entry
be entered to start the vehicle has been Option z
system
adopted. Up to 10 vehicle settings can be
stored in it.
*1: Expect for battery-less model
*2: Model with battery protection function
*3: Model provided with on-vehicle charger
NMF-5
Change in vehicle body color

With the aims of (1) highlighting the changes in the new models and (2) providing a consistent
impression for all the Toyota indoor products, the tonnage stickers and vehicle body colors in the 0.9 to
1.8 ton models to be updated as of August 2012 have been changed as shown below.
The body colors for the 2.0 to 3.0 ton models will remain unchanged.
NMF
White
outline text 0
1
Changed the
painting color from
dark green to dark 2
gray
White
3
embossed text
4
5
G428ZZ501_
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
NMF-6
MAIN DIFFERENCES FROM PREVIOUS MODELS

Applicable Applicable
Item New Model Previous Model
Model Model
General Width 1090/1090 mm 1 ton series 1090/1090 mm 1 ton series
(for SV/FSV mast)
AC: 4.9 kW AC: 4.9 kW
Drive motor 1 ton series 1 ton series
Ø180 × L246 Ø195 × L280
DC: 6.5 kW
1 ton to 1.25 ton
Ø180 × L300
Motor AC: 8 kW
Pump motor 1 ton series 1.35 ton
Ø180 × L249 DC: 8 kW
to
Ø200 × L300
1.8 ton
Steering motor DC: 0.26 kW 1 ton series DC: 0.26 kW 1 ton series
Split type controller Traveling and load
Main controller system for traveling/load 1 ton series handling integrated CPU 1 ton series
handling/main control board
Steering controller with Steering controller with
Steering controller 1 ton series 1 ton series
SAS-R control SAS-R control
Multifunction display DX
(equivalent to the old All-around display with
Control unit all-around type, enhanced overcharging
Display 1 ton series 1 ton series
provided with simple warning and simple load
load meter and wheel meter
indicator as standard)
Automatic equalized
Vehicle-mounted charging Automatic equalized
1 ton series 1 ton series
charger (OPT) Down-time equalized charging
charging
Trailing arm type Trailing arm type
Suspension 1 ton series 1 ton series
suspension suspension
Rotating potential type Rotating potential type
Steering torque detection 1 ton series torque detection 1 ton series
Handle diameter: Ø200 Handle diameter: Ø200
Traveling
unit Automatically controlled Automatically controlled
Brake (front wheel) 1 ton series 1 ton series
hydraulic drum brake hydraulic drum brake
Wire type deadman Wire type deadman
brake brake
Brake (back wheel) 1 ton series 1 ton series
Mechanical disk brake Mechanical disk brake
with power regeneration with power regeneration
Front wheel brake Front wheel brake
1 ton series 1 ton series
control control
SAS-R unit SAS-R control Traction control 1 ton series Traction control 1 ton series
Suspension control 1 ton series Suspension control 1 ton series
Key-off lift lock 1 ton series Key-off lift lock 1 ton series
Body color Orange and dark gray 1 ton series Orange and dark green 1 ton series
Frame Steering plate integrated Steering plate integrated
Instrument panel 1 ton series 1 ton series
resin instrument panel resin instrument panel
Load
handling Mast V mast standard 1 ton series V mast standard 1 ton series
unit
NMF-7
BATTERY
• Battery is provided as an option.
• Only the Shin-Kobe made (STD type) dry battery is provided.
Battery Protection Function
General
In this product improvement, the battery protection function has been newly developed as an optional
item.
The battery protection functions includes the following functions.
• Battery electrolyte level warning (standard)
• Battery electrolyte level sensing vehicle performance limit
• Battery electrolyte temperature warning
• Battery electrolyte temperature sensing vehicle performance limit
• Integrating wattmeter
A battery is the sole energy source for every component of an electric forklift, and one of the essential
functional parts. The currently installed battery is a lead battery whose life is limited because of the
natures of its mechanism and principle and whose deterioration may be accelerated depending on the
conditions under which it is actually used.
Here are the three typical factors that accelerate the deterioration of a battery during use.
(a) Repeated use of over-discharged battery
(b) Use of battery with hot battery electrolyte
(c) Long time use of battery containing not enough battery electrolyte
Number of times of charge/discharge
Useful life y (300 times/year)

Battery life %
Electrolyte temperature °C Degree of discharge %

G428ZZ001_
The effects of all these factors can probably be reduced and the life of the lead battery can be brought
close to the natural life proper to lead batteries by reviewing the operating conditions of the forklift and
performing proper maintenance of the battery.
For the protection of the battery from above factor (a) over-discharge, the "battery over-discharge
warning" function provided as standard is used.
In this product development, the above factors (b) and (c) have been controlled the "battery protection
function" has been newly developed as a means of extending the life of batteries.
This battery protection function monitors the battery condition through the battery electrolyte level and
temperature detection unit provided on the battery, and give a warning and limits the vehicle
performance depending on the determined battery condition. A newly developed integrating wattmeter
has also been established as a new function. This displays the amount of power consumed and CO2
emitted during charging, assisting with energy management.
This function is available in models with on-vehicle chargers.
NMF-8
Function Description
If there is not enough battery electrolyte left, the buzzer sounds
and the battery electrolyte level indicator on the display lights up.
battery electrolyte level warning
This function is provided regardless of adoption of the battery
protection function.
If the time for which the battery is used with not enough battery
Battery electrolyte level sensing
electrolyte exceeds the specified limit, this function limits the
vehicle performance limit
vehicle performance according to the time of use.
If the battery electrolyte temperature reaches the warning level,
Battery electrolyte temperature
the buzzer sounds and the battery overheat warning indicator on
warning
the display lights up.
If the battery electrolyte temperature reaches the warning level,
this function limits the vehicle performance according to the rise in
sensing vehicle performance limit
electrolyte temperature.
The amount of power consumed and CO2 emitted during charging
is shown on a screen at the same level as the display hour
Integrating wattmeter meters.
This function is provided on models installed with an on-vehicle
charger.
Control block diagram
Signal
Battery electrolyte level and
Battery temperature detection unit Communication
Output signal cable

Multi function
display DX
Battery plug
Current sensor Main controller
Electrolyte level sensor

Electrolyte temperature sensor
G428ZZ270_
NMF-9
Name and feature of each component

No. Name Feature
This sensor detects that the battery electrolyte level in a specific
Battery electrolyte level cell has fallen below a certain level. It is placed in a cell near the
1
sensor center of the battery where the battery electrolyte tends to be
reduced more.
This sensor determines the battery electrolyte temperature in a
specific cell of the battery. It is placed in a cell near the center of
Battery electrolyte
2 the
temperature sensor
battery where the battery electrolyte temperature tends to
increase more.
This unit detects signals from the battery electrolyte level sensor
Battery electrolyte level and and the battery electrolyte temperature sensor, converts them
3
temperature detection unit into one signal and sends the signal to the multifunction display
DX. It is installed on the inner surface of the battery.
This sensor detects the battery charging current for counting the
4 Battery current sensor
integrated power
This unit calculates the battery electrolyte level and temperature
based on the data output from the battery electrolyte level and
temperature detection unit and sends the calculation results to
the main controller over a network.
5 Multifunction display DX In addition, it displays a battery electrolyte level warning indicator,
a battery overheat warning indicator, and the battery electrolyte
level performance limit indicator (displayed on the screen), and
sounds a buzzer to inform the operator of the warning level and
vehicle performance limit level.
This unit limits the vehicle performance according to the battery
electrolyte temperature and the time for which the forklift was
continuously used while a battery electrolyte level warning was
given.
6 Main controller
The integrated power is calculated by using internal circuits to
detect the battery voltage and the battery current sensor to detect
the battery charging current. This data is then sent to the
multifunction display DX.
Description of operation
1. Battery electrolyte level warning
If the battery electrolyte level and temperature detection module detects that the electrolyte level has
lowered below a certain level, a warning is given with the buzzer and the battery electrolyte level
warning indicator.
These product enhancements include the addition of a feature whereby a electrolyte-level warning
indicator on the multifunction display DX lights when a warning occurs. The indicator also blinks
when the key is turned off, further improving operator notification.
This makes it possible for the operator to know that there is not enough battery electrolyte left, and to
prompt him or her to supply battery electrolyte.
Electrolyte level warning LED (red) lingts up. G428ZZ136_

NMF-10
2. Battery electrolyte level sensing vehicle performance limit

This function calculates the time for which the forklift was used continuously while a battery
electrolyte level warning was given, and if the time exceeds a certain value, it limits the vehicle
performance according to the time of use.
This time is not counted when the key switch is off, and is reset when the electrolyte level warning is
canceled by supplying electrolyte.
Heavy
Battery electrolyte level warning
Performance limitation
Battery electrolyte level sensing

vehicle performance limit
None
0 16 32
Total time of use under electrolyte level warning conditions [h]
G428ZZ004_
If the performance limit function is activated, the battery electrolyte sensing vehicle performance limit
indicator also lights up, in addition to the electrolyte level warning indicator, and the buzzer sounds
(short beeps) for 5 seconds to warn the operator.
Battery electrolyte sensing vehicle performance limit indicator

(The total time is displayed under the indicator.) Electrolyte level warning LED indicator (red)
remains lit.
G428ZZ137_
Since the vehicle performance is limited by reducing the output of the drive motor, the current to the
drive motor is limited, with the result that the maximum speed, acceleration, hill climbing
performance, and traction performance are reduced.
The effects of performance limitation on these performance increase with loading conditions, and in
some cases, it may become impossible for the forklift to go up a slope.
Keeping the use of the forklift as it is causes the performance limitations to be increased, so if the
battery electrolyte level warning is given, battery electrolyte should be supplied as soon as possible.
NMF-11
3. Battery electrolyte temperature warning

If the battery electrolyte temperature reaches the warning level (approx. 60 °C), a warning is given
with a buzzer and the battery overheat warning indicator on the multifunction display DX.
If the electrolyte temperature reaches the warning level, the warning indicator lights up and the
buzzer sounds (short beeps) for 5 seconds to warn the operator. Also, each time the key switch is
turned on while the electrolyte temperature is above the warning level, the warning indicator lights up
and the buzzer sounds (short beeps) for 5 seconds to warn the operator.
The warning is automatically turned off when the electrolyte temperature falls below the cancel
temperature (approx. 57 °C).
Battery overheat warning LED indicator (red) lights up.

G428ZZ138_
4. Battery electrolyte temperature sensing vehicle performance limit

This function limits the rise in battery electrolyte temperature by limiting the vehicle performance as
soon as the battery electrolyte temperature warning is raised. It increases the limit on the vehicle
performance according to the electrolyte temperature, so it further increases the limit if the
temperature does not stop rising while a limit is placed.
Heavy

Performance limitation
sensing vehicle
performance limit
Adjustable up to 77 °C using the service

function "Tuning No. 33"
None
60 70
Battery electrolyte temperature [°C]
G428ZZ007_
As with the battery electrolyte level sensing vehicle performance limit function, this function limits
the traveling performance, with the result that the maximum speed, acceleration, hill climbing
performance and traction performance are reduced.
The increase in the battery electrolyte temperature during operation is largely caused by battery
charge, in addition to operation itself.
NMF-12
If the electrolyte temperature at the start of the forklift is high or has already reached the warning
level, a limit is placed on the vehicle performance as soon as the forklift starts.
To prevent the temperature from increasing due to charging, please take the following points into
consideration.
• The battery temperature is high immediately after charge. So do not start the forklift immediately
after charge.
• Charging the heavily discharged battery requires more time and causes the electrolyte
temperature to increase more. As a result, it may become necessary, for lack of sufficient time, to
start the forklift before the battery temperature falls sufficiently. It is therefore necessary to avoid
using a battery to such an extent that it is heavily discharged, by taking adequate measures, such
as reviewing the manner of operation.
• Charging the cells evenly requires more time and causes the electrolyte temperature to increase
more. Therefore, it should not be performed the day before the operation, but should be
performed, for example, the two days before the operation so that the electrolyte temperature can
fall sufficiently.
5. Disabling of battery protection functions
If a protection function interferes with operation or if batteries with and without the battery electrolyte
level and temperature detection unit are used in combination because of the nature of the user’s
operation, protection functions can be disabled, as described in the table below.
{: Enable –: Disable
Electrolyte
Electrolyte
Electrolyte level sensing Electrolyte
temperature
Situation Possible disabling setting level vehicle level
sensing vehicle
warning performance warning
performance limit
limit
1. Disabling of battery
electrolyte
temperature
{ { –
sensing vehicle
performance limit
function
The user wants to electrolyte level
disable some functions sensing vehicle { – {
(performance limit performance limit
functions) function
3. Disabling of both
the functions in 1. { – –
and 2.
electrolyte level – {
warning function
The customer wants to
disable all functions.
5. Setting for disabling
The customer wants to
the battery
use batteries with and
electrolyte level and –
without the battery elec-
temperature
trolyte level and temper-
detection unit
ature detection unit in
combination.
The protection functions can be enabled or disabled using the password-protected service function
of the multifunction display DX. Therefore, if so requested by a customer, a dealer's service person
or a person with the same qualification should carry out this operation.
NMF-13
6. Integrating wattmeter
This feature shows the amount of power consumed and CO2 emitted during battery charging on the
multifunction display DX, thereby assisting with energy management.
(1) Monthly integrated power/CO2 emissions display
• Displays the integrated power for each month on a screen on the same level as the hour
meter screens.
• Displays the amount from midnight on the 1st of the month to midnight on the last day of the
month as a one-month total, for a period of up to 3 months.
• Also calculates and displays the CO2 emissions along with the integrated power. The CO2
emission coefficient used as the basic unit can be set in the administrator function screen.
G428ZZ008_
(2) Daily integrated power/CO2 emissions display

• Uses a switch to toggle between the monthly integrated power display screen and a day-by-
day integrated power display.
• Displays the integrated power for each day from midnight to midnight for up to 30 days.
• If charging runs for more than 24 hours, the amount is integrated into the following day's data.
Days on which charging does not occur are not shown. (Dates are run together on the
display.)
• Shows the CO2 emissions in the same way as for the monthly integrated power.
G428ZZ009_
(3) CO2 unit setting

• The CO2 emission coefficient used as the basic unit for calculating CO2 emissions can be set
using the administrator functions.
• The basic unit is not set at shipment (displayed as "-.---"), but once the unit is set, the level of
CO2 emissions is calculated and displayed based on the current integrated power data.
• Customers should set the CO2 emissions coefficient in kg/kWh units by referring to the
information provided by their contracted electricity supplier.
G428ZZ250_
NMF-14
(4) Reset of the integrated power data

• To allow for situations where the forklift user changes, such as when the forklift is rented out,
the integrated wattmeter data can be reset (cleared) using the administrator functions.
• The data that is reset is the monthly integrated power, the daily integrated power and the
amount of CO2 emissions. Because the CO2 emissions coefficient is not reset, the new
coefficient should be set in consultation with the user.
• Note that once the data has been reset, it cannot be recovered.
• Starting the hour meter in the service functions does not clear the data.
G428ZZ011_
NMF-15
Comparative table for effective operating times

Battery capacity Effective operating time
Model
Voltage (V) AH/5hr Hour (h) Minute (m)
Previous Model 48 280 2 50
New Model 48 280 3 05
List of continuous operating time for each charging (S mode)

New Model Previous Model
Battery capacity Continuous operating Continuous operating
z: STD time for each time for each
Model
{: OPT charging: T charging: T
Voltage
AH/5hr Hour Minute Hour Minute
(V)
201 z 3 45 3 25
7FBR10 48 225 - - - 3 35
240 { 4 30 - -
201 z 3 05 2 50
7FBR13 48 225 - - - 3 20
240 { 4 00 - -
280 z 4 45 4 20
7FBR15 48 312 { 5 30 5 00
370 { 6 40 6 05
280 z 4 30 4 05
7FBR18 48 312 { 5 10 4 40
370 { 6 20 5 45
Caution:
• The effective operating time of a new model vehicle is approx. 63% of that of the continuous
operating time.
• The continuous operating time is the time measured in H mode under the Toyota 30m
operation cycle conditions.
• The continuous operating time for each charging in H mode is approx. 80% of that in S mode
and approx. 95% of that in P mode.
NMF-16
Battery specification
Battery list (manufacturer: Shin-Kobe)
STD type
z:STD {:OPT
Battery capacity Model
7 7 7 7
F F F F
Voltage
(AH/5HR) (AH/6HR) B B B B
R R R R
10 13 15 18
165 171
201 209
201 209 z z
240 249 { {
48V
210 218
280 291 z z
312 324 { {
370 384 { {
R300 type Battery replacement specification

z: STD {: OPT
7 7 7 7
Voltage F F F F
R R R R
10 13 15 18
201 209 z z
240 249 { {
210 218
48V
280 291 z z
312 324 { {
370 384 { {
NMF-17
Battery list (manufacturer: GS YUASA)

STD type
z: STD {: OPT
7 7 7 7
F F F F
Voltage
R R R R
10 13 15 18
165 171
201 209
220 228
201 209 z z
48V 240 249 { {
210 218
280 291 z z
312 340 { {
370 384 { {
R300 type Battery replacement specification

z:STD {:OPT
7 7 7 7
F F F F
Voltage
R R R R
10 13 15 18
201 209 z z
240 249 { {
210 218
48V
280 291 z z
312 340 { {
370 384 { {
Battery model list

z: STD {: OPT NMF-18
Battery capacity Single battery Battery case Model

7 7 7 7
Size (mm) Electro- Weight Size (mm)
Voltage Model F F F F
Weight lyte (kg) Weight
(kg) quantity (kg)
Supplier
Tank Overall R R R R
Length Width (l) Length Width Height
height height 10 13 15 18
165 171 VSDX165MH-48 58 158 410 442 11.1 1.9 317 262 956 540 40
201 209 VSFL201M-48 58 158 490 528 12.6 2.3 354 262 956 540 40
201 209 VSFL201M-48 58 158 490 528 12.6 2.3 354 262 956 565 41 z z
240 249 VSI240M 58 158 520 522 14.2 2.3 393 262 956 565 41 { {
48V
210 218 VSFL210A-48 90 158 490 528 16.0 4.6 442 372 956 565 49
Shin-Kobe
280 291 VSFL280-48 90 158 490 522 17.6 4.2 480 372 956 565 49 z z
312 324 VSIL312-48 90 158 520 552 19.6 4.4 528 372 959 565 49 { {
370 384 VSIL370-48 90 158 520 558 21.3 4.0 569 372 956 565 49 { {
165 171 VCD3A 60 158 395 426 10.0 1.9 310 262 956 540 40
201 209 VCF3A 60 158 490 521 12.5 2.4 350 262 956 540 40
220 228 VGF220 60 158 490 521 13.0 2.5 360 262 956 540 40
201 209 VCF3A 60 158 490 521 12.5 2.4 350 262 956 565 41 z z
48V 240 249 VGI240 60 158 520 552 13.5 2.5 376 262 956 565 41 { {
GS YUASA
210 218 VCF3C 90 158 490 521 15.0 4.1 445 372 956 565 49
280 291 VCF4N 90 158 490 521 17.0 3.9 465 372 956 565 49 z z
312 340 VCI4 90 158 520 550 20.0 4.0 535 372 956 565 49 { {
370 384 VGI370 90 158 520 550 21.0 4.1 560 372 956 565 49 { {
NMF-19
Charger list
z:STD {:OPT
Applicable model
Transformer 7 7 7 7
Power Battery Power sup-
Transformer capacity Battery F F F F
supply capacity ply capacity
model (kVA) voltage B B B B
voltage (AH/5H) (50/60Hz)
(50/60Hz) R R R R
10 13 15 18
TR4225E 2.7/2.7 165 to 220 10/10 A z z
TR4312E 200 V 3.6/3.6 48 V 240 to 312 15/15 A { { z z
TR4370E 4.5/4.5 370 15/15 A { {
External charger list (manufacturer: GS YUASA)

{:OPT
Applicable model
Trans- Power
Power 7 7 7 7
Battery former Battery supply
supply Charger Output F F F F
voltage capacity capacity capacity
voltage models plug B B B B
(V) (kVA) (AH/5H) (A)
(V) R R R R
(50/60Hz) (50/60Hz)
10 13 15 18
SG3-69-
4.3/3.8 165 to 240 15/15 { {
45JBY-2
SG3-69-
200 5.4/4.7 280 to 320 20/20 { {
60JBY-2
SG3-69-
7.3/6.5 370 to 445 30/20 { {
80JBY-2 SB175
48
SG3-69- A
4.3/3.8 165 to 240 10/10 { {
45JBY-2
SG3-69-
400 5.4/4.7 280 to 320 10/10 { {
60JBY-2
SG3-69-
7.3/6.5 370 to 445 15/10 { {
80JBY-2
NMF-20
ON-VEHICLE CHARGER
New function and improved point
(1) On the operation panel, charge switch and stop switch are now separated to make the stop
operation to be performed easily.
(2) The charging completion time is now displayed when the charging progress indicator reaches the
8th bar, allowing the operator to see at a glance when charging will be completed. (Fig. 01)
Charging progress indicator
(Fig.01) Charging completion time

G428ZZ271_
(3) Based on the operation day settings, she scheduling of automatic equalized charging is now
automatically adjusted to avoid operation days, making it easier to allocate the time required for
equalized charging.
Note:
Depending on factors such as the customer's charging frequency, automatic equalized charging
may not be carried out on rest days.
Operation day setting
The operation day settings can be configured from the administrator screen on the multifunction
display DX.
By default, all days are set as operation days. (Fig. 02)
(Fig.02)
G428ZZ272_
NMF-21
Description of operation panel
EQUAL LED (yellow)
UP LED (green) NORMAL LED (yellow)
STOP switch START switch
(Fig.03) G428ZZ273_
(1) EQUAL LED (yellow)

LED that light during the equalizing charge.
(2) NORMAL LED (yellow)
LED that light during the normal charge.
(3) UP LED (green)
LED that light when charge is completed. If charge is interrupted due to an error, the LED flashes to
notify the abnormal situation.
(4) START switch
Switch to start normal or equalizing charge.
Simply push to start the normal charge. Push and hold for 2 seconds to start the equalizing charge.
(even during the normal charge, microcomputer will switch to the equalizing charge when
appropriate).
Note:
When the charging switch is pressed briefly, it functions in the same way as the optimal charge
switch in the 2ton/3ton series.
(5) STOP switch
Switch to stop charge.
Description of the multifunction display DX
(the part related to on-vehicle charger)
Multiple screen display area Spanner indicator
Switch (1) Switch (2) Switch (3) Switch (4)
(Fig.04)
G428ZZ274_
(1) Switch (1)

Used to move cursor down on the menu screen.
(2) Switch (2)
Used to display the charge counter while charging.
(3) Switch (3)
Not used by the charger.
(4) Switch (4)
Used for the execution operation on the menu screen, and the stop operation on the charge screen.
(5) Multiple screen display area
Displays the menu screen, charge counter, charge status, and error code.
(6) Spanner indicator
Flashes when some error occurs.
Error code is then displayed describing the charger related error on the multiple screen display area.
NMF-22
Charging procedure
(1) Preparation for charging
First, connect the AC power plug.
This enables AC power, flashes all LEDs on the operation panel, and shows the start screen on
the display. (Fig.05)
After 2 seconds from the start screen, the display turns into the initial screen, and all LEDs on the
operation panel flash. (Fig.06)
Caution:
If the display does not show the start screen and the initial screen, check for the power failure or
breaking of power code.
Initial screen Start screen
(Fig.05) G428ZZ275_ (Fig.06) G428ZZ276_
(2) Routine charge (normal charge)

Pushing the switch on either the operation
panel or the multifunction display DX can start
charging.
• When start charging from the operation
panel
After connecting the AC power plug, push
the START switch on the operation panel.
• When start charging from the display
After connecting the AC power plug, when Switch (1) Switch (4)
the "1.NORMAL CHARGE" menu is (Fig.07) G428ZZ277_
selected, push the switch (4) and hold it for
2 seconds on the initial screen. (Fig.07)
This starts the normal charge, lights the
NORMAL LED on the operation panel, and
shows the charging screen on the display
(shows CHARGE on the display). (Fig.08)
Note:
If the microcomputer determines that it is time to
execute the equalizing charge, the equalizing
charge starts, the EQUAL LED lights, and shows
the charging screen on the display (shows
CHARGE on the display).
(Fig.08) G428ZZ278_
NMF-23
(3) Manual equalizing charge

Pushing the switch on either the operation
panel or the multifunction display DX can start
charging.
• When start charging from the operation
panel
the START switch and hold it for 2 seconds
on the operation panel.
• When start charging from the multifunction Switch (1) Switch (4)
display DX (Fig.09) G428ZZ279_
switch (1) to select the "2.EQUALIZE
CHARGE" menu on the initial screen. In
this state, push switch (4) and hold it for 2
seconds. (Fig.09)
This starts the equalizing charge, lights the
EQUAL LED on the operation panel, and
shows the charging screen on the display
(shows CHARGE on the display). (Fig.10)
(Fig.10) G428ZZ280_
NMF-24
(4) Completion of charge

When charging is complete, the UP LED on
operation panel lights and the display shows
the completion screen. (Fig.11)
When the charge is completed, push the
STOP switch on operation panel or
multifunction display DX switch (4) to turn off
the complete LED, and then disconnect the
AC power plug.
Switch (4)
(Fig.11) G428ZZ281_
Caution:
If you disconnect the AC power plug before
turning off the UP LED, the power failure is
assumed; both LED and display keep the current
status, and charge completion status is held.
(This display behavior is to let users know the
completion of charge even when a power failure
occurs after the charge completes).
During the above status, if you push the STOP
switch on operation panel or multifunction
display DX switch (4), the UP LED goes off and (Fig.12) G428ZZ282_
the display shows the initial screen. (Fig.12)
After initial timer test screen is displayed, the
display turns off if no action is taken for some
time or if the switch (4) is pressed while "4. END"
is selected in the initial screen menu.
If you perform the traveling or load handling
operation, or turn ON/OFF the key switch, the UP
LED goes off and the display also goes off.
Switch (4)
(Fig.13) G428ZZ283_
If a power interruption occurs during charging,

the LED on the charger operation panel that was
lit during charging starts blinking and the power
interruption screen appears on the display.
(Fig. 14)
Charging resumes when power is restored.
(Fig.14) G428ZZ284_
NMF-25
(5) Stop of charge

To stop charging before charging completed,
disconnect the AC power plug after stopping
charging.
Pushing the STOP switch on either the
operation panel or the multifunction display
DX can stop charging.
• When stop charging from the operation
panel
Push the STOP switch on the operation Switch (4)
panel. (Fig.15) G428ZZ285_
• When stop charging from the display
Push switch (4) and hold it for 2 seconds
on the charging screen. (Fig.15)
This stops charging, all the LEDs on the
operation panel go off, and the display returns
to the initial screen.
(6) Display of charge counter
The charge counter can be confirmed regardless of connection of the AC power plug.
Confirm from the start screen (Fig.16)
• When the AC power plug is disconnected
In a state of key-off and disconnecting the AC power plug, push switch (1) and hold it for 2
seconds, the start screen (charge count) will be displayed for 2 seconds.
• When the AC power plug is connected
Connect the AC power plug, the start screen (charge count) will be displayed for 2 seconds.
Switch (1)
(Fig.16) G428ZZ286_
Confirm from the menu on the initial screen (Fig.17,18)

• Common operation regardless of connection of the AC power plug
After the startup screen appears, you can display the battery charge counter by pressing the
switch (1) in the initial timer test screen twice and then pressing the switch (4) while "3.CHG
COUNT" is selected.
Switch (1) Switch (4)

(Fig.17) G428ZZ287_
(Fig.18) G428ZZ288_
NMF-26
Confirm during charging (Fig.19)

• Only when the AC power plug is connected
Pushing switch (2) on the display during charging enables the charge count to be displayed.
Charge counter
(Fig.19)
Switch (2) G428ZZ289_
"What is charge count"

The charge counter counts the number of times charged using the on-vehicle charger while checking for
damage due to battery load (travel time and voltage, temperature, etc. during travel).
Where "1" appears on the charge counter display, the number of times charged is approximately once.
However, because the increments to the charge counter may vary depending on the detected data
values and battery capacity level when charging starts, this value is only an approximate guide.
Note:
This function enables number of times charged by an on-vehicle charger to be counted. But it is
not available for the off-vehicle charger.
The charge counter can be returned to "0" by using the service function when replacing the battery.
NMF-27
DRIVE MOTOR
Aim of development
Improved efficiency
New model
General
• The new drive motor has been made more compact by adopting a frameless structure.
• Motor efficiency has been improved by optimizing the core shape and the coil specifications.
Field core Terminal block
Rotor Field coil

G428ZZ013_
Specifications
Item
Rated output
4.9 kW
(60 minutes)
Body size Ø180 mm × L246 mm
Weight 26 kg
Previous model
General
G428ZZ012_
Specifications
Item
Rated output
4.9 kW
(60 minutes)
Weight 25 kg
NMF-28
PUMP MOTOR
Aim of development: improved efficiency and use of an AC motor
Previous model
General
G428ZZ014_
Specifications
Models
7FBR10, 13 7FBR(S)15, 18
Item
Rated output
6.5 kW 8.0 kW
(60 minutes)
Body size Ø180 mm × L300 mm Ø200 mm × L302 mm
Weight 28 kg 30.5 kg
NMF-29
New model
General
• The motor has been changed from a DC motor to an AC motor so that one standard type is used for
the 1 ton series drive motor.
• Offers the advantages of having no brushes or commutators, making the motor smaller while also
boosting output.
Terminal block
Field core
Rotor Field coil
G428ZZ015_
Specifications
Item
Rated output
8.0 kW
(5 minutes)
Weight 25 kg
NMF-30
ELECTRICAL CONTROLLER SYSTEM

General
1. Controller configuration
The controller system to drive AC motor in this model has
• Microcomputer-assisted inverter control,
• CAN (Controller Area Network) communication function between main controller, drive / pump AC
drivers, and multifunction display.
• Multifunction controller system that combines existing technology the latest innovations in
electronic technology, such as continuing to use existing products for the EPS controller and the
AFS, remote control and multi-lever.
In these product enhancements, an AC motor has been used in the pump motor as well as in the
drive motor (previous models used DC motors).
All electronic units on every new model are connected to each other through a high-speed CAN
network. As a result, sharing and interlocking capabilities have been improved and new features
(OPT) such as "battery protection function/integrating wattmeter" and "PIN code entry system" have
been achieved.
Previous model
Point to Point
Communication
Display
Main Controller
(Drive/Pump)
EPS Controller
Drive Motor Pump Motor PS Motor

(AC) (DC) (DC)
New model
Point to Point
Communication
Main Controller
Multifunction
display DX EPS Controller
CAN
Communication
Drive Motor Motor Driver Motor Driver Pump Motor PS Motor

(AC) (Drive) (Load handling) (AC) (DC)
G428ZZ016_
NMF-31
2. Characteristics of AC system
In general, AC motor generates higher output than equivalent size of DC motor.
The output characteristic of an AC motor-driven system is determined by the combination of the
alternate current and frequency output by the motor driver. The power select function has been
achieved by mapping the combinations of alternate current and frequency most suitable for multiple
output characteristics and by switching between maps with a switch.
AC motor maximum
output
Torque
AC power system output

characteristics
DC power system output

characteristics (DC motor
maximum output)
rpm
[Comparison of the output characteristics of motor of the same size]

An AC motor produces a higher output, compared with a DC motor of the same size,
so its output can be set more flexibly.
G428ZZ017_
On DC system, the output characteristics are determined by the controller output voltage. The
maximum output becomes the DC motor output when the battery voltage is fully applied (chopper
duty is 100%). Therefore, the output will be decreasing as the battery voltage goes to low due to
discharging.
Compared to this, AC system has capable to maintain high performance as changing the
combinations of amplitude and frequency of AC motor control according to the battery state of
charge. “Power Keep” function is implemented by this control.
AC and DC power system output

characteristics with fully charged battery
Torque
AC power system output characteristics

with discharged battery
DC power system
output characteristics
with discharged battery
rpm
[Comparison of output characteristics when the battery is discharged]
In comparison between an AC motor and a DC motor that have the same output
characteristic when the battery is fully charged, the output of the AC motor is
maintained even when the battery is discharged, while the output of the DC motor is
reduced.
G428ZZ018_
NMF-32
3. Controller configuration
(1) Main controller
In this model change, the configuration was reviewed and the traveling controller and load
handling controller were integrated into the main controller. Also, the controller was made smaller
in size by using smaller parts for printed circuit boards and changing the configuration, and its
weight was reduced by changing the case material from steel to aluminum and plastic.
The degree of protection provided by enclosures (IP code) is equivalent to IP20.
(2) Motor driver
In this model change, the motor driven portion of the traveling and load handling controller was
separated as a motor driver from the controller. A trench MOS-FET with less power loss than
conventional devices was adopted as the main device.
The degree of protection provided by enclosures (IP code) is equivalent to IP65.
(3) EPS controller
The same EPS controller as in existing models is used.
(4) Power supply controller
A power supply controller has been provided to supply power to the EPS controller.
Previous model
Drive and load handling EPS controller

New model controller
EPS controller
Power supply controller

Main controller
Drive motor Pump motor

driver driver G428ZZ019_
Caution:
• Do not disassemble the main controller or the motor driver.
• Although spare parts are available for the controller of the previous model, the main controller
and motor driver for the new model are supplied as assemblies. Keep in mind that if
disassembled, the main controller or the AC driver is not covered by the guarantee.
NMF-33
BASIC FUNCTION
General
In these product enhancements, an anti-rollback function has been added along with various functional
improvements in response to market demand. In addition, a range of functions have been made possible
through linkages between controllers.
Refer to the following items for details.
[Basic function]
• Traveling function
• Load handling function
• Power steering function
• Power keep function
• Power select function
• Power control select function
• Auto power off function
• Thermal protect function
• Remaining battery charge calculating function
• Diagnostic function
• Over-discharge warning function
• Key on return-to-neutral function
NMF-34
System configuration
Input Output
Sensor/Switch Actuator
1 Accelerator sensor 15 Drive motor *1
2 Brake limit switch 16 Pump motor *2
3 Material handling lever switch (Front)

[Multi function display DX]
4 Material handling lever switch (Rear)
Speed meter
5 Reach limit swicth Battery capacity indicator
19 Main Controller
Power select indicator
12 Diagnostic code display
6 Tilt limit switch
Diagnostic mode indicator
Overheat warning indicator
7 Attachment lever switch Low speed setting indicator
Onboard buzzer
8 Rear speed sensor *1
9 Temperature sensor (Drive motor) *1
10 Speed sensor (Pump motor) *2
11 Temperature sensor (Pump motor) *2
[Multi function display DX]

12 Low speed setting switch
Power select switch
Controller
13 Steering torque sensor 17 Lift lock valve

20 EPS
14 Tire angle sensor 18 PS motor
G428ZZ260_
*1: The inputs of the rear speed sensor and the temperature sensor (Drive motor), and the output of the
drive motor are carried out from the drive motor driver.
*2: The inputs of the speed sensor (Pump motor) and the temperature sensor (Pump motor), and the
output of the pump motor are carried out from the pump AC driver.
NMF-35
Structure and feature of each component

1. Name of each component
19,20 3,4
12 1
5,6,7
13
17
10,11,16
8,9,15
14,18
2
G428ZZ021_
No. Name No. Name

1 Accelerator sensor Multifunction display DX
2 Brake limit switch 12 Low speed setting switch
3 Material handling lever switch (Front) Power select switch
4 Material handling lever switch (Rear) 13 Steering torque sensor
5 Reach limit switch 14 Tire angle sensor
6 Tilt limit switch 15 Drive motor
7 Attachment lever switch 16 Pump motor
8 Rear speed sensor 17 Lift lock valve
9 Temperature sensor (Drive motor) 18 PS motor
10 Speed sensor (Pump motor) 19 Main controller
11 Temperature sensor (Pump motor) 20 EPS controller
NMF-36
2. Feature of each component

No. Name Feature
This sensor installed on the accelerator lever unit detects the
1 Accelerator sensor operating angle of the accelerator lever and the operating
direction to drive forward/backward.
This switch installed near the brake pedal detects the
2 Brake limit switch
operation of the brake.
The material handling lever switch (Front) detects the lift
3 Material handling lever switch (Front) operation. This switch is mounted at the root of the lever for
models with a standard lever.
The material handling lever switch (Rear) detects the lift
4 Material handling lever switch (Rear) operation. This switch is mounted at the root of the lever for
The reach limit switch detects the reach operation. This switch
5 Reach limit switch is mounted at the root of the lever for models with a standard
lever.
The tilt limit switch detects the tilt operation. This switch is
6 Tilt limit switch mounted at the root of the lever for models with a standard
lever.
The attachment lever switch detects the attachment
7 Attachment lever switch operation. This switch is mounted at the root of the lever for
Two sensors installed on the drive motor detect the speed of
8 Rear speed sensor
the motor and the direction of rotation of the motor.
This sensor installed on the drive motor detects the
9 Temperature sensor (Drive motor)
temperature of the motor.
This sensor installed on the pump motor detects the rotating
10 Speed sensor (Pump motor)
speed of the motor.
This sensor installed on the pump motor detects the
11 Temperature sensor (Pump motor)
temperature of the motor.
The multifunction display DX built into the instrument
panel displays a range of information depending on the
12 Low speed switch
Power select switch
vehicle status and operation mode. The multifunction
display DX is also used to configure various functions.
This sensor mounted at the lower part of the steering wheel
13 Steering angle sensor
detects the position of rotation of the steering wheel.
This sensor installed on the drive unit detects the position of
14 Tire angle sensor
the tire.
15 Drive motor The drive motor drives the front wheels of the vehicle.
The pump motor drives the oil pump, and supplies a hydraulic
16 Pump motor
oil to the load handling system.
This valve is equipped with a solenoid. When a voltage is
applied with a controller, the valve blocks the flow of oil from
17 Lift lock valve
the lift cylinder to the oil tank to prevent the fork from going
down.
The PS motor uses the EPS controller to assist with tire
18 PS motor
steering when the vehicle is steered.
The main controller controls the basic functions such as
19 Main controller
traveling and load handling functions.
The PS motor is controlled in response to handle
operation via the steering torque sensor, tire position via
20 EPS motor
the tire angle sensor, and traveling speed pulses from
the main controller.
NMF-37
Traveling function
1. Regenerative brake system
(1) Regenerative brake (Accelerator lever OFF)
When the accelerator is released during traveling, the regenerative brake works and recovers
electric braking energy into the battery. It increases the operating time, extends the life of the
brakes and brings a smooth and powerful deceleration feeling.
The adjustment of this regenerative brake feeling is obtained by using the service function of the
display. The adjustment image is shown as follows.
Speed TUNING No.10

Slow
TUNING No.7
Strong Quick TUNING No.9
Weak
Quick Weak
Strong
Accelerator ON Slow Accelerator OFF Time

TUNING No.8
G428ZZ022_
(2) Regenerative brake (Releasing the brake pedal)

When the brake pedal is released, the regenerative brake force is obtained. This regenerative
brake extends the service life of brake and operation hours.
(3) Regenerative brake (Switchback)
In case of the switchback operation, the regenerative brake force is generated according to the
amount of the accelerator lever operations. This regenerative brake extends operation hours. At
the same time, the smooth, powerful and quick regenerative brake feeling is obtained. Thereby,
the traveling operationality is improved. The adjustment of this regenerative brake feeling is
obtained by using the service function of the display. The adjustment image is shown as follows.
GENERAL TUNING
TUNING No.14
Speed Speed
Slow
TUNING No.13 TUNING No.11

Quick Weak Strong
Weak
Strong Slow Quick
Switchback Quick Time Switchback Slow Time

TUNING No.15 TUNING No.12
G428ZZ023_
NMF-38
2. Anti-rollback function
These product enhancements include the addition of an anti-rollback function that limits the traveling
speed to the rollback speed or lower when the accelerator lever is released on a slope.
After the accelerator lever is released on a slope, the vehicle stops briefly and then slowly speeds up
to the rollback speed. This makes it easier to work on a slope.
The speed limit above which the vehicle does not roll back can be adjusted within a range of 0.5 km/h
to 4 km/h in steps of 0.5 km/h.
Additionally, the anti-rollback function can also be disabled using the service function (option set
function) to comply with user's request.
Caution:
• This function uses the regenerative braking force generated by the drive motor, so it does not
work when the key switch is turned off or the battery plug is disconnected.
• The speed at which the vehicle rolls back on a slope varies depending on the gradient of the
slope and the loading conditions.
3. Maximum speed limitation function
If the maximum speed limit is set, this function prevents the vehicle from running at speed higher
than the speed limit. It relieves the operator from the need to finely adjust the accelerator in order to
observe the speed limit, and the administrator from the need to keep watch on the speed limit.
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h, using the administrator function
of the multifunction display DX.
4. Low speed setting function
If the low-speed setting switch on the multifunction display DX is pressed, this function prevents the
vehicle from running at speed higher than the predetermined speed. This function is useful especially
for customers who set different speed limits for indoor and outdoor traveling. It is possible for the
operator to change the speed setting. *1
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h.
* 1: When locked with a menu option, the speed setting can be changed only with the administrator
function.
NMF-39
Load handling function

1. Conventional lever
A high efficiency load handling control has been achieved due to the combination of the manual
spool valve used on the previous model and an AC motor control in this product development.
The load handling feeling can be adjusted on a lever-by-lever basis using the service function of the
multifunction display DX. An image of this adjustment is shown in the figure below.
2. Multi-lever and AFS
As with previous models, a multi-lever and AFS have been newly set as options. The adjustment of
this load handling feeling is obtained by using the service function of the multifunction display DX.
[GENERAL TUNING]
Motor Fast
speed
TUNING No.26 Lift

TUNING No.27 Tilt
Slow TUNING No.28 Attachment 1
TUNING No.29 Attachment 2
Neutral Lever stroke
[LEVER TUNING]
Lift/Tilt/Attachment 1/Attachment 2
TUNING * Only the first lift raise setting is enabled.

INCH
Fast
Speed
TUNING ACC
Narrow
Fast Slow
Wide
* Items on the lever tuning screen
TUNING
cannot be adjusted at MAX and DEC.
START
Slow
Start lever
operation Lever stroke
G428ZZ024_
NMF-40
Power steering function

As in existing models, the PS motor provides a power steering function that assists with tire steering in
response to the handle operation torque. At high traveling speeds, the PS motor steering assistance is
cut back to reduce instability. An end-shock prevention control is also provided to reduce the impact on
the operator's hands when the end stopper is reached during handle operation.
Power keep function
As with previous models, the power keep function is provided to maintain the battery performance even
when the battery is significantly discharged. This function works only in P, S and E modes, and it can be
disabled using the service function (option setting function) of the multifunction display DX.
For this new model, the performance characteristic of the battery as significantly discharged can be
adjusted using the service function (tuning function) of the multifunction display DX. An image of this
adjustment is shown in the figure below.
[General tuning]
Performance
TUNING No.4
100 [%] Power keeping

Up
P, S and E modes
All modes
Down
Discharge level
G428ZZ025_
Power select function

The traveling and load handling power control mode can be switched in five levels: H, P, S, E and
Original by using the selector switch on the multifunction display DX. When the power control mode is
switched, the maximum speed, acceleration, deceleration and lift up speed change.
H mode is a mode in which importance is placed to operation efficiency and maximum performance is
delivered for both traveling and load handling.
P mode is a mode in which operation efficiency and operation time are well-balanced.
S mode is a mode in which importance is placed to operation time.
Power control select function
Five traveling and load handling modes, H, P, S, E mode, and Original mode, are selectable by the
selection switch on the multifunction display DX. According to the power mode, the maximum speed,
acceleration, deceleration and lift up speed are changed.
Auto power off function
If the operator leaves the vehicle with the key switch ON, the vehicle becomes the state of key switch
OFF when the preset time is out. This function prevents waste of energy. On this model, this timer can be
set up by 1-minute.
To restart the vehicle, turn off the key switch, and then, turn it on.
The auto power off time is set to 15 minutes by factory default.
Thermal protect function
The main controller, motor driver and motor have the temperature sensors. If an abnormally high
temperature is detected, this function will turn on the overheast warning indicator and display where
overheats on the multifunction display DX, and it will be informed to the operator. And the performance of
vehicle is limited to prevent overheating.
NMF-41
Remaining battery charge calculating function

This is the function which computes the remaining capacity based on decrease of battery voltage. The
remaining capacity is displayed on the multifunction display DX as the current battery level.
Using the service function of the display, the multifunction display DX of the remaining capacity can be
adjusted.
Diagnostic function
This function detects the abnormal condition of various sensors, such as the accelerator pedal sensor,
and various actuators, such as the drive motor. When an abnormal condition is detected, the error code
is displayed on the display. And the fail-safe processing is performed to the vehicle.
Over-discharge warning function
If traveling or load handling operation is carried out while the battery capacity is at the over-discharge
warning level, a visual and audible warning will be given to inform the operator that the battery is over-
discharged. In addition to that, a limit will be placed on the vehicle performance. Through these
operations, the battery is protected and the operator is prompted to charge the battery.
The battery discharge level that triggers the warning function can be adjusted in the service functions
(tuning functions) on the multifunction display DX. For details, see the figure below.
For the new model, the action taken to limit the vehicle operation when an over-discharge warning is
given has been changed in order to protect the battery more positively. Also, it has become possible to
switch the operation limit mode with the service function (option setting function) of the multifunction
display DX. For details, see the figure below.
Normal tuning level [No.1]
Amount of
discharge 1 2 3 4 5 6 7 8
[%] Default
50
60
70 Battery warning
80 Battery indicator blinks.
90
100
Over-discharge warning
Ten segments of the battery
indicator blink.
No warning
G428ZZ026_
OPTION SET
“D-LIM MODE” Restriction processing
(Traveling limit mode)
A The amount of accelerator operation is restricted at 50%.
B
No limitation.
[Default]
Key on return-to-neutral function

If the key switch is turned on when the accelerator lever has not returned to neutral position, this function
limits the output of the drive motor. Then, it can prevent the vehicle departing suddenly.
In this event, the problem is detected as a neutral error in the accelerator lever angle sensor and an error
code is shown on the multifunction display DX. However, if the accelerator sensor is functioning
normally, the operator has to return the accelerator lever to the neutral positions in order to depart.
NMF-42
DRIVE UNIT
Difference from previous model
Changes
• The gear ratio has been changed from 31 to 24.
• The maximum motor speed has been changed from 5300 rpm to 4090 rpm.
• The gear set has been changed.
• The structure of the axle shaft bearing has been changed.
• Lock nut
Tightening torque: 237 to 355 N.m
• Preload of the axle shaft bearing has been changed: 14 to 30 N
• A collar and a sim have been added between the axle shaft bearings.
• A bearing with lower rolling resistance has been adopted on the pinion shaft bearing.
Drive gear
Gear case cover
Idle gear
Pinion shaft bearing
Gear case
Gear set Drive wheel shaft
Collar added
Lock nut
Sim added
Axle shaft bearing
G428ZZ027_
NMF-43
MULTI FUNCTION DISPLAY DX

GENERAL
The multifunction display DX adopts a full-dot matrix LCD panel to display various information in an
easy-to-see way. It is provided not only with the functions of displaying and providing vehicle information,
such as vehicle speed and remaining battery capacity, but also with functions that allow the operator (or
the administrator) to set the vehicle performance.
Difference from the multiple screen display provided on the previous model (before improvement)
• The wheel indicator (with direction indicator) has been provided as standard.
• The power meter has been added.
• The maintenance hour meter has been added.
• The integrating wattmeter has been added as an option.
In addition to these functions, it has also a maintenance function, a feeling adjustment function and a
specification setting function as service functions.
The degree of protection provided as a single part (IP code) is equivalent to IP42 (except for peripheral
part of connectors), and that provided by enclosures is equivalent to IPX4.
(6) (8)
(9)
(10)
(7) (11)
(5)
(1) (2) (3) (4)
G428ZZ051_
No. Description
(1) Switch (1): Low speed setting switch/Down switch
(2) Switch (2): Power select switch/Left switch
(3) Switch (3): Time or date select switch/Right switch
(4) Switch (4): Meter mode select switch/Enter switch
(5) Multiple screen display area
(6) OPS indicator
(7) Low speed setting indicator
(8) Spanner indicator
(9) Overheat warning indicator
(10) Battery electrolyte temperature warning indicator
(11) Battery electrolyte level warning indicator
NMF-44
FEATURES LIST
Operationality Condition for available functions
—: Display only STD: BUILT-IN
: Operator available OPT: OPTION
: Operator available when menu lock setting is “NO“
: Administrator only (protected by the administrator password)
Multifunction
Features Operation
Display DX
Calendar — STD
Initial screen after Maximum speed limiter — STD
key-on
Overspeed alarm — STD
(Indicates the
function status) Brake valve (accumulator) auto accumulating OFF — STD
Traction control OFF — STD
STD
OPS indicator — Except for steel cabin spec. at extremely
low temperature and in long time
Low speed setting indicator — STD
Spanner indicator — STD
Overheat warning indicator — STD
Battery electrolyte level warning indicator — STD
OPT
Battery overheat indicator — With battery protection function
Battery electrolyte level sensing vehicle performance OPT
limit indicator — With battery protection function
STD
Charging progress indicator — When charger is installed.
Battery capacity indicator — STD
Status display
Digital speedometer — STD
Power select (ESPH/original) indicator — STD
Swing lock indicator — STD
Front wheel brake ON indicator — STD
Traction control ON indicator — STD
STD
Load meter — Except for Canada spec.
Maintenance indicator — STD
Menu lock indicator — STD
Power meter — STD
Date/Time — STD
Wheel indicator — STD
Direction indicator — STD
Key switch on hour meter — STD
Lap time meter — STD
Traveling hour meter — STD
Load handling hour meter — STD
Meter
Traveling/Load handling hour meter — STD
Odometer — STD
Trip meter — STD
Maintenance hour meter — STD
NMF-45
Operationality Condition for available functions
—: Display only STD: BUILT-IN

: Operator available OPT: OPTION
: Operator available when menu lock setting is “NO“
: Administrator only (protected by the administrator password)
Multifunction
Features Operation
Display DX
OPT
Models installed with an on-vehicle
Meter Integrating wattmeter — charger and provided with battery pro-
tection function
Battery over-discharge warning — STD
Low battery level warning — STD
Overheating warning — STD
Low temperature warning — STD
Battery electrolyte level warning — STD
OPT
Warning Battery overheat warning — With battery protection function
function
OPT
Return to neutral warning for load handling OPS — With AFS or multi-lever
Diagnostic code display — STD
Over speed alarm — STD
Traveling and load handling warning during charging — STD
Battery pull-out warning — STD
Clock set STD
STD
Power select (ESPH) function (with ESP as original)
Travel power control level setting STD
Load handling power control level setting STD
Low speed setting STD
Maximum speed limitation setting STD
Overspeed alarm setting STD
STD
Load meter zero setting Except for models with AFS
Maintenance hour meter setting STD
Auto power off time setting STD
Setting Secondary password registration for administrator STD
function Menu lock setting STD
STD
Operation day setting Models installed with an on-vehicle
charger
OPT
CO2 unit setting charger and provided with battery pro-
tection function
OPT
Integrating wattmeter clear setting charger and provided with battery pro-
tection function
STD
Charging reservation timer setting Models installed with an on-vehicle
charger
Support function PIN code entry and setting OPT
for PIN code entry
With PIN code entry system
system Profile setting
NMF-46
SCREEN
(1) Initial screen after Key-on
Initial screen is displayed for 2 seconds after key-switch is turned on.
G428ZZ254_
Display Description
13/10/2011 (THU) Calendar is displayed.
Indicate if the Maximum speed limitation in active setting.
G428ZZ053_
Indicate if the overspeed alarm is in active setting.
G428ZZ054_
Indicate if the traction control is in invalid setting.
G428ZZ055_
Indicate if the accumlator auto accumlating is in invalid setting.
G428ZZ056_
NMF-47
(2) Status screen

After the initial screen display, status screen is displayed.
The wheel indicator is displayed during a stop and the speedometer is displayed instead during
traveling.
The power select mode and the menu lock indicator * are displayed soon after the initial screen.
The power meter screen is displayed instead after 5 seconds.
Press switch (2) to confirm the power select mode selected currently during displaying power
meter screen.
*: Displayed when the menu lock is in active setting by the administrator.
Screen during stop (displayed for 5 seconds after

Initial screen after Key-on the Key-on initial screen has been displayed)
Power select indicator

Menu lock indicator
Screen during traveling Speedometer Screen during stop Wheel indicator

Battery
capacity
indicator
Power meter Function ON indicator

Clock/calendar display area
Switch (2)
G428ZZ057_
Note:
Screen during traveling
On the Australia and New Zealand spec. models,
the direction indicator is displayed on the Direction indicator
traveling screen instead of the speedometer.
G428ZZ258_
NMF-48
DETAIL DESCRIPTION
1. Indicator
Indicator Description
OPS indicator
This indicator lights when the operator is not properly seated.
G428ZZ058_
Low speed setting indicator

This indicator goes on or off each time the low speed setting switch is pressed. The
indicator lights when the low speed setting function is enabled.
It does not light when the low speed setting function is disabled (off).
The low speed can be set on both the operator setting screen and the
administrator setting screen. When menu lock is enabled, this setting can be made
only on the administrator setting screen.
G428ZZ059_
Spanner indicator
This indicator blinks and the buzzer sounds if any vehicle’s error are detected.
At that time, an error code is displayed in the multiple screen display area.
G428ZZ060_

This indicator lights up and the buzzer sounds if the temperature of the traveling/load
handling motor rises excessively.
At the same time, the overheated part is also displayed in the multiple screen display
G428ZZ061_
area.
Battery electrolyte temperature warning indicator (with battery protection function)

If the battery electrolyte temperature rises above the specified temperature, this
indicator lights up, the buzzer sounds and the output is limited. This function helps
prevent a reduction in the battery life.
If the activation of this function hinders the operation, it may be disabled using the
service function.
G428ZZ062_
Battery electrolyte level warning indicator

1. Without battery protection function
This indicator lights if a lack of battery electrolyte is detected. If a lack of battery
electrolyte is detected when the key switch is turned on, the buzzer also sounds
for several seconds. Moreover, if a lack of battery electrolyte is detected while
the key switch is off, this warning indicator blinks to prompt the operator to add
battery electrolyte.
2. With battery protection function
This indicator lights if a lack of battery electrolyte is detected. If a lack of battery
electrolyte is detected when the key switch is turned on, the buzzer also sounds
for several seconds. Moreover, if a lack of battery electrolyte is detected while
the key switch is off, this warning indicator blinks to prompt the operator to add
If the vehicle has been operated exceeding the specified hour without enough
battery electrolyte, the battery electrolyte level sensing vehicle performance limit
indicator is displayed in the multiple screen display area along with the hour.
G428ZZ063_ This warning prevents from operation without enough battery electrolyte, by
prompting the operator to supply battery electrolytes.
NMF-49
2. Battery capacity indicator

This indicates amount of charge in the battery in
10 stages.
G428ZZ064_
3. Speedometer
Speedometer indicates the vehicle speed
digitally in 1 km/h.
G428ZZ065_
4. Power select indicator

Pressing switch (2) while the power meter being displayed on the status screen, the currently
selected power mode (E, S, P, H or Original) will be displayed instead of the power meter. With the
power indicator being displayed, pressing switch (2) each time switches to each power select mode
as shown below.
Moreover, if switch (2) has not been operated for a long while, it will return to display the power
meter.
When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled or
disabled using a set of options provided in the service function.
When the menu lock function is enabled with an administrator function, the power mode cannot be
changed.
G428ZZ066_
When H mode lock

is disabled
G428ZZ067_
NMF-50
5. Power meter
This meter displays the level of energy currently being output (regenerated). Because this allows you
to identify operations that consume high levels of energy, such as rapid acceleration, it contributes to
vehicle operation that takes energy consumption into account.
Pressing switch (2) while the power meter being displayed, the power select indicator will be
displayed instead.
Regeneration Output
G428ZZ068_
6. Function ON indicator
(1) Maintenance indicator
This indicator is displayed if the time counted
by the maintenance hour meter exceeds the
preset hour. If the key switch is turned on in
such a situation, the buzzer sounds for
approximately 5 seconds. If this time reaches
the preset hour while the operation, this
indicator lights up, without sound is emitted at
that time.
G428ZZ069_
(2) Menu lock indicator

Pressing switch (2) on the status screen the
menu lock indicator is displayed when the
menu lock is set to “YES” (enabled).
If the operation for opening an operator setting
menu is carried out while the menu lock
indicator is lit, this indicator blinks to indicate
that the operation is invalid.
G428ZZ070_
(3) Battery electrolyte level sensing vehicle

performance limit indicator
(With battery protection function)
If the vehicle has been operated exceeding
the specified hour without enough battery
electrolyte, the battery electrolyte level
sensing vehicle performance limit indicator is
displayed in the multiple screen display area
along with the hour, and also the vehicle
performance is limited. The battery electrolyte
level warning remains lit.
G428ZZ071_
NMF-51
(4) Swing lock indicator

This indicator is displayed when the Swing
lock cylinder is locked.
G428ZZ072_
(5) Front wheel brake ON indicator

This indicator is displayed when the front
brake is in ON state during traveling.
G428ZZ073_
(6) Traction control ON indicator

This indicator is displayed when the traction
control is in ON state due to a slip occurs on
the drive tire during traveling and switch-back.
G428ZZ074_
(7) Date and Time display

This function switches between date and time
each time the date-clock select switch is
pressed on the status screen.
Date
Clock
G428ZZ075_
NMF-52
(8) Multi meter display screen

Press switch (4) on the status screen, the display changes in a sequence of “Key-ON hour meter,
Lap time meter”, “Traveling hour meter, Load handling hour meter, Traveling/Load handling hour
meter”, “Odometer, Trip meter”, “Maintenance hour meter” and “Status screen”.
On models with battery protection function and installed with an on-vehicle charger, an integrating
wattmeter is displayed after the maintenance hour meter screen.

OPT
G428ZZ218_
NMF-53
(a) Key on hour meter

This hour meter integrates the time
while the key switch is turned on. (The
Key ON hour
login time is counted when selecting
meter
PIN code entry system.)
Lap time meter
(b) Lap time meter
Lap time is integrated while the key
switch is turned on. (The login time is
counted when selecting PIN code
entry system.) Pressing switch (1) for
G428ZZ077_
more than 2 seconds resets it.
(c) Traveling hour meter
Traveling hour meter
while the drive motor is working such
as the power running mode or Load handling
regenerative braking mode. Time hour meter
while the drive motor is freewheeling,
is not integrated.
(d) Load handling hour meter
Traveling/load handling hour meter
G428ZZ078_
while the pump motor is working such
as the power running mode for the
load handling operations. Time while
the pump motor is rotating in only
steering operation, is not integrated.
(e) Traveling/Load handling hour meter
while the traveling or pump motor is
working such as the power running
mode or regenerative braking mode.
Of course, it does not integrate the
time either when the drive motor is
freewheeling or pump motor is
rotating in only steering operation.
(f) Odometer
The traveling distance of the vehicle is
integrated.
(g) Trip meter Odometer
This meter integrates the traveling Trip meter
distance that can be reset. Pressing
switch (1) for more than 2 seconds
resets it.
G428ZZ079_
(h) Maintenance hour meter Maintenance hour meter

The preset service interval time and
the current elapsed time are
displayed.
The maintenance hour meter Elapsed time
integrates the elapsed time while the
Set value
key switch is turned on (login time for
PIN code entry system). It also
continues to integrate the elapsed
time even if it exceeds the preset G428ZZ219_
service interval time.
NMF-54
(i) Integrating wattmeter

(models installed with on-vehicle
charger and provided with battery
protection function)
G428ZZ220_
(9) Wheel indicator

The symbol “ ” indicates the direction of travel of the vehicle. When the vehicle speed is
detected, the speedometer is displayed instead.
On the Australia and New Zealand spec. models, the speedometer is not displayed even when
the vehicle speed is detected.
Left turn Straight ahead Right turn
G428ZZ082_
(10) Direction indicator

This indicator indicates the position where the forward/reverse switch is placed. When the vehicle
speed is detected, the speedometer is displayed instead.
On the Australia and New Zealand spec. models, the speedometer is not displayed even when
the vehicle speed is detected.
Forward Neutral Reverse
No indicator
G428ZZ083_
NMF-55
(11) Load meter (Except Canada spec.)

When the lift lever is returned to neutral from lifting up operation, the load weight is displayed on
the status screen. With this meter, the operator can tell the weight of the load with an unit of 0.01
ton. When the load weight is less than 100 kg, it is displayed as “0.00t.”
The load weight is displayed for about 5 seconds each time the lever is returned to neutral. It is
not displayed when the vehicle speed is detected.
The load weight display time can be adjusted with a turning function included in the service
function.
G428ZZ084_
On the Australia and New Zealand spec. models, the load meter is displayed as shown below.
G428ZZ258_
Caution:
• This function is not intended to be used for commercial transactions or authentication
purposes.
• As the load weight is determined in a simplified way by measuring the lift cylinder pressure, it
should not be used as the basis for determining whether the forklift is overloaded.
• When the load is in the uppermost position, the load weight is displayed larger than the actual
one because of the residual pressure in the cylinder after a relief of pressure.
• In cold environments, such as refrigerated warehouses, where the viscosity of the operating
fluid increases, the load weight may not be displayed correctly.
Load weight display screen when load is lifted high. (Except for FV mast with the mast height 3 m
or less.)
The load meter provided in previous models is not capable of correcting the weight of the load
lifted high on the FV or FSV mast.
This is because the lift cylinder holding pressure changes under the weight of the inner and
middle masts. For the new model, it has become possible to calculate the weight of the load lifted
high on the FV or FSV based on the lift cylinder size and the pressure data at the zero point.
However, when a load is lifted high, the measurement accuracy decreases because of a
deflection of the mast and the friction in the cylinder. Therefore, the load weight should be
measured when the load is not lifted high, where the load meter is displayed as shown below.
Also when a load is lifted high on the V mast, the load meter is displayed as shown below.
Only Australia and New Zealand spec.
G428ZZ085_ G428ZZ259_
NMF-56
(12) Warning functions

(a) Low battery level warning
When the battery becomes below the
preset level, the battery level indicator
blinks. When the operator turns the
key switch from OFF to ON with this
condition, a buzzer will sound for 5
seconds to warn the operator.
G428ZZ086_
(b) Battery over-discharge warning

When the battery becomes over
discharged below the preset level in
active “low battery level warning”, all
segments in the battery level indicator
blink and a buzzer sounds to warn the
operator.
G428ZZ087_
The chart below shows relations of “Battery over-discharge warning”, “Low battery level warning” and
“Tuning No.1”.
Discharged Normal tuning setting level [No.1]

amount 1 2 3 4 5 6 7 8
[%] Initial value
50
60 Low battery level warning

Battery capacity indicator blinks.
70
80
90 Over-discharge warning
10 segments of battery capacity
indicator blink.
100
No warning
G428ZZ088_
NMF-57
(c) Overheat warning

Overheat indicator lights and buzzer sounds to warn the operator in the case of
temperature of drive motor, pump motor, motor driver or main controller risen over a certain
level.
In warning stage, the buzzer sounds for 5 seconds.
In error stage, the sound is kept until the error is recovered. Although error code is not
displayed on the display, it is logged in DIAG MEMORY.
Overheating part is displayed on the display.
Display information
PSCR: EPS controller
C/R: Main controller
DCR: Drive AC driver
PCR: pump AC driver
DM: Drive motor
PM: Pump motor
G428ZZ089_
When overheated, the vehicle
performance will be limited.
(d) Low temperature warning
If the temperature of the motor driver is extremely low, low temperature part is displayed on
the display and buzzer sounds to warn the operator. In warning stage, the buzzer sounds
for 5 seconds.
Display information
COLD DCR: Drive motor driver
COLD PCR: pump AC driver
At a low temperature, the vehicle
performance will be limited.
G428ZZ090_
(e) Return to neutral warning for load handling OPS (AFS or multi-lever)
The buzzer sounds is emitted to warn the operator that, when stand on the floor after the
OPS ON while operating the load lever, the operator needs to return all the load handling
levers to neutral in order to start the load handling operation.
(No warning is displayed on the multifunction display DX.)
(f) Traveling and load handling warning during charging (for models with an on-vehicle
charger)
If the accelerator operation or load handling operation is performed with an AC power plug
inserted, a warning sound is emitted to warn the operator that the traveling or load handing
operation is restricted.
(g) Battery pull-out warning
The buzzer sounds is emitted to warn the operator that, when traveling or load handling
operation is performed with the battery pulled out, the operator needs to stop the traveling
or load handling operation.
NMF-58
(h) Diagnostic code display

When diagnosis is activated, the
spanner indicator blinks and a buzzer
sounds to warn the operator that
some abnormality has occurred on the
vehicle.
Also, up to six diagnostic error codes
are displayed on the screen.
G428ZZ091_
(i) Overspeed alarm

When the vehicle speed exceeds the
preset speed, the speed indicator
blinks and a buzzer sounds to inform
the operator of over speeding. Unlike
low speed setting, there is no speed
limitation applied even if the speed
exceeds the preset speed.
This speed setting can be done on
both operator menu screen and
administrator menu screen. G428ZZ092_
But, this setting can be done only on administrator screen when the menu lock setting is
“YES”. (Operator menu screen is not displayed.)
In this case, administrator needs to release the “Menu lock” for operators, or to set this
setting function for each operator in the administrator’s menu.
NMF-59
SETTING FUNCTIONS
1. Clock set
The year, month, day, time and 12/24-hour display can be set.
Press switch (3) on the status screen for more than 2 seconds, and clock set screen is displayed.
Functions of switches on the clock set screen:
Switch (1): Exit (without set)
Switch (2): Decrease the selected (blinking) value
Switch (3): Increase the selected (blinking) value
Switch (4): Enter the selected (blinking) value and proceed to the next item
By pressing switch (4) at “MINUTES” setting, the setting is completed and the screen returns to the
status screen.
The setting value on clock set can also used on the integrating wattmeter provided as a battery
protection function (OPT).
Please set the date and time properly.
If a wrong date is set, the integrated value on the integrating wattmeter may be reset.

G428ZZ221_
2. Power select function

The power mode (E, S, P, H or Original) and its indication change each time switch (2) is pressed on
the status screen.
When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled or disabled
using a set of options provided in the service function.
When the menu lock function is enabled with an administrator function, the power mode cannot be
switched.
G428ZZ066_
When H mode lock

is disabled
G428ZZ067_
NMF-60
Power control setting function (Orignal mode)

Press the switch (2) on the status screen for more than 2 seconds, the power control menu
screen will be displayed. (If the menu lock is set to “YES” in the administrator function, the power
control setting menu screen is not displayed.)
When selecting the PIN code entry system model, this item can be set by profile setting function.
(This screen is not displayed.)
G428ZZ222_
(a) Travel power control

Select the “DRIVE POWER” on the
power control menu screen to display
the drive power control screen.
Switch (2): Decrease the level
Switch (3): Increase the level
Switch (4): Return to power control
setting menu screen
G428ZZ223_
When the H mode lock setting is “YES”, H mode is not available to select. Please refer to
a service function about the way to release the H mode lock.
(b) Load handling power control
Select the “LIFT POWER” on the
power control menu screen to display
the load handling power control
screen.
Switch (2): Decrease the level
Switch (3): Increase the level
Switch (4): Return to power control
setting menu screen
G428ZZ224_
When the H mode lock setting is “YES”, H mode is not available to select. Please refer to
a service function about the way to release the H mode lock.
NMF-61
3. Setting menu for operator

Press switch (1) on the status screen for more than 2 seconds will display the setting menu screen
for operator.
When the menu lock is set to “YES” in the administrator function, the setting menu screen is not
displayed.
In this case, administrator needs to release the “Menu lock” for operators, or to set this setting
function for operators in the administrator’s menu.
In addition, in the case of the model with PIN code entry system, the setting menu screen is not
displayed except Height selector option.
Select an item with switch (1), and press switch (4) to display each setting screen.

G428ZZ225_
(a) Low speed setting

The speed limit of the low-speed
setting function can be changed.
Switch (2): Setting speed limit to slow
Switch (3): Setting speed limit to fast
Switch (4): Returning to setting menu
screen
G428ZZ226_
It is adjustable from 2 to 20 km/h by 1 km/h.

If the operator set the speed to more than 20 km/h, the low speed function is disabled. In
that case, “OFF” is displayed.
When selecting the model with PIN code entry system, this item can be set by profile
setting function. (This screen is not displayed.)
NMF-62
(b) Overspeed alarm setting

The speed to activate the overspeed
alarm function can be changed.
Switch (2): Setting threshold speed
down
Switch (3): Setting threshold speed up
screen
G428ZZ227_
It is adjustable from 5 to 20 km/h by 1 km/h.

If the operator set the speed to more than 20 km/h, the low speed setting function is
disabled. In that case, “OFF” is displayed.
When selecting the PIN code entry system model, this item can be set by profile setting
function. (This screen is not displayed.)
NMF-63
ADMINISTRATOR FUNCTIONS
Administrator can set the following items.
Administrator functions are protected with password so that the general operators cannot change these
settings.
1. Administrator menu list
(1) Model without PIN code entry system
Setting menu Setting screen
Power mode select*1
Power control functions Setting of travel power control level*1
Setting of load handling power control level*1
Speed setting of low speed*1
Travel functions Speed setting of maximum speed limiter
Speed setting of overspeed alarm*1
Load handling functions Zero-point setting of load meter (multifunction display DX only)
Setting of maintenance hour meter
Setting of auto power off
Setting of administrator’s secondary password
Setting of menu-lock
Vehicle management functions (Models installed with an on-vehicle charger)
CO2 unit setting
(Models installed with an on-vehicle charger and provided with
battery protection function)
Integrating wattmeter clear setting
*1: When menu lock setting is released, the operator can set it.
(2) Model with PIN code entry system

Setting menu Setting screen
Registry of PINs
Change of profile assignment
PIN code entry functions
Delete of PINs
(PIN code entry system)
Profile data setting
Change of initial PIN
Load handling functions Zero-point setting of load meter
Setting of maintenance hour meter
Setting of auto power off
Setting of auto log off
Setting of administrator’s secondary password
Setting of menu-lock
Vehicle management functions
(Models installed with an on-vehicle charger)
CO2 unit setting
Integrating wattmeter clear setting
PIN code (PIN: Personal Identification Number)
NMF-64
2. Password Entry Procedure

Caution:
• Always operate switches on the multifunction display DX with a fingertip. If a sharp pointed
tool is used, the switch may be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from
the beginning.
Step Display Operation Vehicle response
Press switch (2) and When pressing the

switch (4) at the same switches, a short beep
1
time for more than sounds, and after 2 seconds
2 seconds. another short beep sounds.
G428ZZ100_
Press switch (3) within

2 A short beep sounds.
10 seconds.
Switch (3)
G428ZZ101_
Press switch (3) within

10 seconds.
Switch (3)
G428ZZ101_
When pressing the

Within 10 seconds, press
switches, a short beep
switch (2) and switch (4)
4 sounds, and after 2 seconds
at the same time for
repeated short beeps
more than 2 seconds.
sound.
G428ZZ100_
When the secondary password has been set:

Password screen is displayed. Enter the password.
5
When the secondary password has not been set:
Skip this screen.
G428ZZ228_
6 Administrator menu screen is displayed automatically.
G428ZZ229_
NMF-65
3. Operation Procedure
(1) Input the password on the status screen to display the administrator menu screen.

G428ZZ230_
(2) Press switch (2) or switch (3) to select the

desired menu tab.
The selected tab is emphatically displayed
and items that can be set are displayed below.
G428ZZ231_
(3) Press switch (1) to select the item, and press

switch (4) (enter) to display the menu or
setting screen for each function.
G428ZZ106_
Note:
Select the return tab on the Administrator Menu
screen, and press switch (4) (enter) to display the
status screen.
G428ZZ107_
NMF-66
4. ADMINISTRATOR MENU screen (Model without PIN code entry system)

Power control setting menu Vehicle management setting menu
Traveling setting menu
Load handling setting menu Return to the status screen
G428ZZ234_
NMF-67
(1) Power Control Setting Menu screen

This menu screen can set the drive and lift
power control function.
G428ZZ229_
(a) Power select screen

The power select mode (E,S, P, H or
Original) can be selected by pressing
switch (2) or switch (3) on the power
select screen by shifting to the
corresponding indicator position.
Switch (2): SJEJESPHJHJPJS...
Switch (3): SJPJHJESPHJE
Switch (4): Returning to power control G428ZZ235_
setting menu screen
This is the same as the one in the operator functions.
When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled
or disabled using a set of options provided in the service function.
(b) Drive power control level setting The
drive power of the original mode can
be set in five steps.
Switch (2): Select the lower level
Switch (3): Select the higher level
Switch (4): Returning to power control
setting menu screen
G428ZZ223_

When H mode lock is enabled, H mode cannot be selected.
H mode lock can be enabled or disabled using a set of options provided in the service
function.
(c) Lift power control level setting
The lift power of the original mode can
be set in five steps.
Switch (2): Select the lower level
Switch (3): Select the higher level
Switch (4): Returning to power control
setting menu screen
G428ZZ224_

When H mode lock is enabled, H mode cannot be selected.
H mode lock can be enabled or disabled using a set of options provided in the service
function.
NMF-68
(2) Travel Setting Menu Screen

This menu screen can set the travel control
function.
G428ZZ236_
(a) Low speed setting screen

The limit speed of the Low-speed
setting function can be changed.
Switch (2): Setting traveling speed
down
Switch (3): Setting traveling speed up
screen
G428ZZ098_

It is adjustable from 2 to 20 km/h with a step of 1 km/h. If the operator set the speed to
more than 20km/h, the low speed function is disabled.
In that case “OFF” is displayed.
(b) Maximum speed limit setting screen
The limit speed of the Maximum
speed limiter can be changed.
down
screen
G428ZZ237_
It is adjustable from 2 to 20 km/h with a step of 1 km/h. If the operator set the speed to
more than 20km/h, the maximum speed limit function is disabled. In that case “OFF” is
displayed.
(c) Over speed alarm setting screen
The speed to activate the over speed
alarm function can be changed.
down
screen
G428ZZ227_
It is adjustable from 3 to 20 km/h with a step of 1 km/h.

If the operator set the speed to more than 20km/h, the over speed alarm function is
disabled In that case “OFF” is displayed.
NMF-69
(3) Load Handling Setting Menu Screen

This menu screen can set the Load Handling
control function.
G428ZZ238_
(a) Load meter zero point adjustment

screen
Zero point of the load meter is
adjusted.
V and SV mast
At low lift height (ZERO SET):
Set the mast approximately vertical, G428ZZ239_
and raise forks at height of

approximately 500 mm from the
ground.
Pressing switch (1) for more than 2
seconds will reset the indicated value
to 0. In that case “OK” is displayed.
Switch (4): Return to menu screen
G428ZZ240_
FV and FSV mast

At low lift height (ZERO SET1):
Set the mast approximately vertical,
and raise forks at height of
approximately 500 mm from the
ground.
Pressing switch (1) for more than 2
seconds will reset the indicated value
to 0. In that case “OK” is displayed.
G428ZZ241_.
Switch (4): Next screen
At high lift height (ZERO SET2):
[FV mast with the mast height 3 m or
less]
ZERO SET2 is not required.
"NG" is displayed when performing
reset, but it will not be regarded as an
error.
Switch (4): Returning to menu screen
G428ZZ242_
[FV mast and FSV mast other than those mentioned above]
Set the mast approximately vertical, and raise the rear lift cylinders to a height of
approximately 100 mm.
Pressing switch (1) for more than 2 seconds will reset the indicated value to 0. In that
case “OK” is displayed.
Switch (4): Return to menu screen
NMF-70
(4) Vehicle Management Setting Menu Screen

This menu screen can set the vehicle
management function.
G428ZZ243_
(a) Maintenance hour meter setting

screen
Time for planned maintenance hour
meter can be set from 10 to 2000
hours by 10-hour increments between
10 and 200 hours, while 50-hour
increments between 200 and 2000
hours.
Switch (2): Decreasing set time
Switch (3): Increasing set time G428ZZ244_
Pressing switch (1) for more than 2 seconds will reset the current value to 0.
(This reset operation does not cause the stored set value to change.)
The maintenance hour meter can be turned off by reducing the maintenance time below
10 hours with switch (2).
If turned off, the maintenance hour meter will not make a notification with the
maintenance indicator or a warning sound, although it will retain the elapsed time data.
NMF-71
(b) Auto power off time setting

The time to activate the auto power off
function can be changed.
Switch (2): Decreasing set time
Switch (3): Increasing set time
It is adjustable from 2 to 60 minutes
with a step of 1 minute. Auto power off
function is disabled by selecting “OFF”
G428ZZ245_
which is next to “60 min”.
(c) Administrator’s secondary password setting screen
The administrator can register the secondary password.
The secondary password can be registered by continuing to press switch (1) for 2
seconds after entering it by using switch (1) to (4). If press the switch (4) for 2 seconds or
more, the screen returns to the menu screen without memorizing it.
Administrator should manage the secondary password so that it doesn’t get unknown.
Even if it has got unknown, the service staff can clear it on the service menu.
G428ZZ246_
NMF-72
(d) Clear password

Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s
secondary password setting screen.
If press the switch (4) for more than 2 seconds, the screen returns to the menu screen.
G428ZZ247_
(e) Menu lock screen

Setting change by an operator can be
limited.
If “YES” is selected, the following
restrictions are activated.
• Operator setting menu screen not
available
• Power select setting screen not
available
• Power mode not switchable G428ZZ248_
If the operator attempts to use the operator setting menu screen, configure the power
select settings or switch the power mode display when setting changes are restricted, the
menu lock indicator is displayed to the left of the power select indicator.
Switch (2): Selecting “Yes”
Switch (3): Selecting “No”
Conditions required to release the menu lock differ depending on the setting of the option
set item “menu lock spec.”.
The menu lock spec. is set to B by factory default.
If the menu lock spec. is set to A:
The menu lock release setting (NO) is valid until the key switch is turned off. It changes to
“YES” when the key switch is turned off.
If the menu lock spec. is set to B:
The menu lock release setting (NO) is valid until it is returned to “YES” on the menu lock
screen.
No menus are locked before the start of the hour meter.
NMF-73
(f) Operation day setting screen

(Only for models installed with an on-
vehicle charger)
The operation day can be set.
Switch (1):
Set or Cancel the operation day.
Switch (2):
Move a day to be set leftward.
Switch (3): Not operation day
Move a day to be set rightward. Operation day
G428ZZ249_
Switch (4):
Returning to menu screen
Setting the operation days adjusts the timing of automatic equalized charging so that it
takes place on rest days.
(g) CO2 unit setting screen
vehicle charger and provided with
The CO2 unit can be changed.
Switch (2): Decrease the setting value
Switch (3): Increase the setting value
G428ZZ250_
You can set values between 0.001 and 2.000 kg/kWh in 0.001 increments. If you select
"-.---" that precedes 0.001 kg/kWh, the amount of CO2 emissions is no longer displayed.
Customers should set the CO2 emissions coefficient in kg/kWh units by referring to the
information provided by their contracted electricity supplier.
NMF-74
(h) Integrating wattmeter clear screen

vehicle charger and provided with
The record of the integrated power
can be cleared.
Pressing Switch (1) for more than 2
seconds will clear the record of the G428ZZ126_
integrated power.
When you clear the integrated power
record, the charging amount for the
3-month period reverts to 0 kWh and
the charging data for the last 30-day
period is displayed as "-".
G428ZZ127_
(1) End Menu Screen

Switch (4): Returning to status screen
G428ZZ107_
NMF-75
5. ADMINISTRATOR MENU screen (Model with PIN code entry system)
PIN code entry menu Vehicle management setting menu
Load handling setting menu
Return to the status screen
G428ZZ251_
NMF-76
(1) PIN Code Entry System Setting Menu Screen

This menu screen can set the PIN code entry
function.
G428ZZ252_
(2) Load Handling Setting Menu Screen

This menu screen can set the Load Handling
control function.
For details, refer to “Load handling Setting
Menu Screen” (W/O PIN code entry system).
G428ZZ238_
(3) Vehicle Management Setting Menu Screen

This menu screen can set the vehicle
management function.
For details, refer to “Vehicle Management
Setting Menu Screen” (W/O PIN code entry
system).
G428ZZ243_
(4) End Menu Screen

Switch (4): Returning to status screen
G428ZZ107_
NMF-77
SERVICE FUNCTIONS
General
In the multifunction display DX, aside from the general functions that an operator or an administrator normally use,
the following service functions for use by the service staff for vehicle maintenance and specification setting are also
provided.
The service functions are protected by the password so that the important internal data will not be damaged by the
customer’s misuse.
Service Function List
When used
Function Description Vehicle Controller
Others
delivery replacement
Displays the electrical
system status and reads the Upon vehicle
Analyzer – –
error information detected abnormality
by controllers.
Makes fine adjustment of
{ As requested
Tuning traveling and load handling –
*2 by customer
functions.
Sets each vehicle option and {
Specification setting – –
other specifications. *1 *2,*3
Option set
Each control function Enables or disables each {
– –
enable/disable control function. *2,*3
Updates voltage values of
Traveling function {
sensor signals under the – –
/SAS-R *2,*4
standard vehicle condition.
Matching { When it is
Load meter Sets the load meter.
*3 necessary
Makes the speedometer {
Tire data – –
reading appropriate. *2
Starts the counts on the hour
{
Meter start meter, odometer, trip meter { –
*3
and maintenance meter.
Enables simultaneous
operation of traveling and Before starting
Demo mode – –
load handling before starting the hour meter
the hour meter.
Initialize a set value with the { When it is
To default set –
default value. *2,*3 necessary
Others menu Service secondary pass- Sets the service secondary { When it is
–
word setting password. *3 necessary
Administrator’s
Delete the administrator’s { As requested
secondary password –
secondary password. *3 by customer
clear
Resets the charger counter { When it is
Reset of charger counter –
to 0. *3 necessary
Adjusts the contrast of the
{ As requested
Contrast multifunction display DX –
*3 by customer
screen.
*1: This is for matching the controller and multifunction display DX control to the options or functions installed on
the vehicle and not for enabling/disabling each option or control function itself.
*2: Main controller
*3: Multifunction display DX
*4: EPS controller
NMF-78
SERVICE PASSWORD
Caution:
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch
may be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from
the beginning. If the SERVICE MENU cannot be displayed after several attempts, the system
may be faulty.
Password Entry Procedure
Step Display Operation Vehicle response
When pressing the switches, a

Press switch (2), switch (3)
short beep sounds, and after 2
1 and switch (4) at the same
seconds another short beep
Switch (2) Switch (4) time for more than 2 seconds.
sounds.
Switch (3) G42804ZZ001_
Press switch (4) within 10

seconds.
Switch (4)
G42804ZZ002_
Press switch (1) within 10

seconds.
Switch (1)
G42804ZZ003_
Within 10 seconds, press When pressing the switches, a

switch (2) and switch (3) at short beep sounds, and after 2
4
the same time for more than seconds repeated short beeps
Switch (2) Switch (3) 2 seconds. sound.
G42804ZZ004_
When the service secondary password has been set:

Secondary password screen is displayed. Input the secondary
5 password.
When the service secondary password has not been set:
This screen is skipped.
G42804ZZ005_
6 Service function initial screen is displayed for 5 seconds.
G42804ZZ006_
7 ANALYZER MENU screen is automatically displayed.
G42804ZZ007_
NMF-79
ANALYZER
General
The analyzer functions are designed to make it easy to check and troubleshoot the control system by displaying its
state through communications between the multifunction display DX and each controller.
By switching the multifunction display DX to analyzer mode, it becomes possible to check the operation state of
each sensor and actuator used for the traveling, load handling, EPS, SAS-R and OPS functions, and also to read
information about errors detected by controllers, which helps check the operation state of each function and reduce
the repair time in the event of a failure.
Thus, the use of the analyzer function ensures fast and easy servicing.
The analyzer functions include the following:
(1) Diagnosis memory function (DIAG MEMORY)
The controller stores up to 10 error codes (diagnoses) that refer to problems that have previously
occurred in the electrical system. The diagnosis function reads these error codes and shows
them on the display.
Each error code is displayed with its detection time in the form of the key ON hour meter reading.
(2) In/out monitor function (I/O MONITOR)
This function shows the analog input value from the sensors in the traveling, material handling,
EPS, SAS-R and OPS systems on the display. By monitoring this display, you can judge the
quality of the input/output signal from each circuit or sensor.
(a) I/O TEMP/VOLT
Displays the temperature of the functional components relating to electrical systems along
with the analog input voltages detected by the controllers for each potential.
(b) I/O TRAVELING
Displays the ON/OFF states of switches related to traveling and swing control and the
analog input voltages from related sensors.
(c) I/O M. HANDLING
Displays the ON/OFF states of switches related to material handling control and the analog
input voltages from related sensors.
(d) I/O STEERING
Displays the analog input voltages from sensors for the EPS control system.
(e) I/O OTHERS
Displays the ON/OFF states of other switches and the analog input voltages from related
sensors.
(3) Active test function (ACTIVE TEST)
In this function, an operation signal (ON or OFF signal) is forcibly output to the selected item so
that the operation of that function can be checked.
(4) Program version display (VERSION)
This enables you to view the program version for each controller.
(5) Current error code display
This provides a single display showing the error codes for currently active errors in top-right
corner of the I/O MONITOR and ACTIVE TEST screens.
NMF-80
Analyzer Screen Item List

Screen Display
Analyzer menu screen Description
No. item
1. DIAG MEMORY 1/2 to 2/2 1 to 10 Indications of errors occurred
TDM Drive motor temperature
TDMDH Drive AC driver heat sink temperature
1/6
TDMDB Drive AC driver board temperature
TDMDC Drive AC driver capacitor temperature
TPM Pump motor temperature
TPMDH Pump AC driver heat sink temperature
2/6
TPMDB Pump AC driver board temperature
TPMDC Pump AC driver capacitor temperature
2. I/O TEMP/VOLT TMCB Main controller board temperature
3/6
(Temperature/Voltage) TPSDB EPS controller board temperature
TSLLT Battery temperature
4/6
TDSP Display board temperature
B48V Battery voltage
5/6 VBKY Voltage after key switch
VBMB Voltage after MB contactor
VDMD Drive AC driver main circuit voltage
6/6 VPMD Pump AC driver main circuit voltage
VBBTS Battery voltage (EPS input)
SPEED Drive speed
SPDPS EPS traveling speed input
1/5 Accelerator sensor1 voltage
VRA
Accelerator sensor2 voltage
SWBK Brake limit switch
VRTRA Tire angle sensor voltage
SH Lifting height switch
2/5
SPLF Load sensor voltage
3. I/O TRAVELING SPDPS EPS controller-input traveling speed
(Traveling/Swing control) Drive motor rpm
3/5 SPDDM
Target rpm
Speed sensor 1 (Drive motor) voltage
SSD
Speed sensor 2 (Drive motor) voltage
4/5
Drive motor current sensor1 voltage
CSDM
Drive motor current sensor2 voltage
SPDPSL EPS controller-input traveling speed (front LH)
5/5 SPDPSR EPS controller-input traveling speed (front RH)
SPDPS EPS controller-input traveling speed (rear)
NMF-81
Screen Display
Analyzer menu screen Description
No. item
SRC Reach limit switch
SWLF Lift limit switch
SWAT1 Attachment 1 switch
1/4
SDM Floor switch
SWT Tilt limit switch
SWAT2 Attachment 2 switch
4. I/O M.HANDLING
SH Lifting height switch
(Load handling control) 2/4
SPLF Load sensor voltage
Pump motor rpm
3/4 SPDPM
Target rpm
SSP Pump AC driver rotation sensor voltage
4/4 Pump AC driver current sensor1 voltage
CSPM
Pump AC driver current sensor2 voltage
VRTRA Tire angle sensor voltage
5. I/O STEERING
1/1 SPDPS EPS controller-input traveling speed (rear)
(EPS control)
SSTT Steering torque sensor voltage
CSBAT Battery current sensor voltage
1/2
6. I/O OTHERS DOPT Not used
(Others) SPA Accumulator switch
2/2
VBBA Battery pull-out input
SWING
Forcible swing lock solenoid operation
SOL
7. ACTIVE TEST BRAKE L Forcible brake valve solenoid (weak) operation
1/1
(Operation test)
BRAKE H Forcible brake valve solenoid (strong) operation
FAN Cooling fan operation
DISPLAY Multifunction display DX program version
1/2 MAIN C/R Main controller program version
PS EPS controller software version
8. VERSION
(Version) DM
Drive AC driver program version
DRIVER
2/2
PM
Pump AC driver program version
DRIVER
NMF-82
1. TUNING
This feature performs fine adjustment of traveling and load handling controls.
When receiving requests from users, such as the request to weaken the acceleration off
regenerative braking force, various settings levels can be changed on the tuning screens.
Tuning functions has 85 items (included spare items)
Level (*: Initial setting value)
No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery capacity warning and
No.1 Fast * Slow Disabled
battery over-discharge warning.
Slow Fast
No.2 Battery charge indicator calibration No.1 *
decrease decrease
Insensi-
No.3 Battery charge indicator calibration No.2 Sensitive *
tive
Motor torque when the battery discharge has Power Power
No.4 *
proceeded down keep
No.5 To be used *
Insensi-
No.6 Accelerator lever sensitivity * Sensitive
tive
No.7 Acceleration torque Weak * Strong
No.8 Acceleration soft-start Slow * Quick
No.9 Regenerative braking torque at accelerator-off Weak * Strong
No.10 Regenerative braking soft-start at accelerator-off Slow * Quick
No.11 Acceleration torque at switch-back Weak * Strong
No.12 Acceleration soft-start at switch-back Slow * Quick
No.13 Regenerative braking torque at switch-back Weak * Strong
No.14 Regenerative braking soft-start at switch-back Slow * Quick
No.15 Regenerative braking soft-stop at switch-back Slow * Quick
No.16 Accelerator traction torque Weak * Strong
No.17 To be used *
Slow
No.18 Slope regeneration speed Quick
*
No.19 To be used *
No.20 To be used *
No.21 Traveling output when turning Weak * Strong
Maximum speed limitation during backward Quick

No.22 Slow
traveling *
Quick
No.23 Low speed setting during backward traveling Slow
*
No.24 To be used *
No.25 To be used *
Quick
No.26 Pump motor output during lift up operation Slow
*
Pump motor output during tilt forward and backward Quick
No.27 Slow
operation *
NMF-83

No. Item
1 2 3 4 5 6 7 8
Slow
No.28 Pump motor output during reach operation Quick
*
Pump motor output during the attachment
No.29 Slow * Quick
operation *
(Not used) Pump motor output during the
No.30 Slow * Quick
attachment 2 operation
No.31 To be used *
No.32 Load meter display time Short * Long
Temperature at which the battery temperature

Low
No.33 protection function limits the vehicle performance in High
*
the maximum
No.34 Traction control start level Low * High
No.35 Traction control start level during regeneration Low * High
*:The pump motor output of the attachment levers 1 and 2 are in common.
NMF-84

Menu No. Item
1 2 3 4 5 6 7 8
START Not used *
INCH Not used *
LIFT
MAX Not used *
DOWN
ACC Not used *
DEC Not used *
START Play at the beginning of lift up operation Small * Wide
INCH Inching speed during lift up operation Slow * Quick
LIFT
MAX Not used *
UP
ACC Acceleration speed during lift up operation Weak * Strong
DEC Deceleration speed during lift up operation Weak * Strong
START Not used *
INCH Not used *
TILT
MAX Not used *
FWD
ACC Not used *
DEC Not used *
START Play at the beginning of tilt operation Small * Wide
INCH Not used *
TILT
MAX Not used *
BWD
ACC Acceleration speed during tilt operation Weak * Strong
DEC Deceleration speed during tilt operation Weak * Strong
START Not used *
INCH Not used *
RCH
MAX Not used *
OUT
ACC Not used *
DEC Not used *
START Play at the beginning of reach operation Small * Wide
INCH Not used *
RCH
MAX Not used *
IN
ACC Acceleration speed during reach operation Weak * Strong
DEC Deceleration speed during reach operation Weak * Strong
START Not used *
INCH Not used *
ATT1
MAX Not used *
PUSH
ACC Not used *
DEC Not used *
Response at the start of the attachment
START Small * Wide
operation *
INCH Not used *
ATT1 MAX Not used *
PULL
Acceleration during the attachment
ACC Weak * Strong
operation *
Deceleration during the attachment
DEC Weak * Strong
operation *
START Not used *
INCH Not used *
ATT2
MAX Not used *
PUSH
ACC Not used *
DEC Not used *
NMF-85

Menu No. Item
1 2 3 4 5 6 7 8
(To be used) Play at the beginning of the
START Small * Wide
attachment 2 lever pull operation
INCH Not used *
ATT2 MAX Not used *
PULL
(To be used) Acceleration speed during the
ACC Weak * Strong
(To be used) Deceleration speed during the
DEC Weak * Strong
*:The pump motor output of the attachment levers 1 and 2 are in common.
NMF-86
2. OPTION SET
• The option set function is used to fit the specifications of the controller and the multifunction display
DX to the options actually equipped on the vehicle. The option set items are not functioning on the
vehicle that doesn’t actually mount them even if the OPTION SET enables them.
• When main controller or multifunction display DX is replaced, it is necessary to reset them
according to the vehicle specifications.
Option Set Item List
Switching settings
Indication Description Setting Setting
Indication Indication
content content
DISP MODE *1 Setting the display language J Japanese I English
Setting the traveling speed display
MPH *1 YES mph NO Km/h
unit
DATE TYPE *1 Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
Adjust the battery capacity indicator A1: Not used / A2: Battery provided locally
B-TYPE *1
calculation B1: Models provided with battery / B2: Not used
Battery electrolyte level and tem- A: Not provided, B: Previous type (electrolyte level unit),
B UNIT *1
perature unit C: Electrolyte level and temperature unit
B LEVEL ALM *1 Electrolyte level warning YES Enabled NO Disabled
H MODE Setting to enable/ disable H mode
*1 YES Enabled NO Disabled
LOCK lock
MENULOCK Lock release until Lock release
Menulock release specification A B
SPEC key-off until set to “YES“
AFS, multi-lever, remote controller
AFS *1 YES Enabled NO Disabled
specifications
BUZZER
Not used - / - / -
SPEC
SPD ALM2 Not used YES Not used NO Not used
Setting to enable/disable wheel A: Not provided, B: Displayed when the vehicle speed is 0 km,
WHEEL IND *1
indicator C: Always displayed
POWER
*1 Power meter indicator YES Enabled NO Disabled
METER
LOAD METER *1 Load meter display YES Enabled NO Disabled
CHARGE REC *1 Integrating wattmeter display YES Enabled NO Disabled
RAMP CONT Slope control setting YES Enabled NO Disabled
TRC CONT Traction control setting YES Enabled NO Disabled
Brake valve (accumulator) auto
ACCUM CONT YES Enabled NO Disabled
accumulating setting
Traction restric-
Traction restric-
Setting the traction limitation mode tions according
D-LIM MODE *1 A tions regardless of B
at over-discharge warning to discharge
discharge level
level
B LEVEL LIMIT *1 Battery electrolyte level protection YES Enabled NO Disabled
B TEMP LIMIT *1 Battery electrolyte temp protection YES Enabled NO Disabled
POWER KEEP Power keep YES Enabled NO Disabled
CHARGER
*1 For models with on-vehicle charger YES Enabled NO Disabled
UNIT
ACCEL TYPE *1 Accelerator stage setting W Wide N Narrow
BACK
Not used - Not used - Not used
BUZZER
STOP LAMP Not used - Not used - Not used
*1: These items are set according to the type of each vehicle before shipment from the factory.
NMF-87
3. Others
(1) Hour meter start
Used to make the multi meter start to count
up.
The power select mode after the meter starts
differs depending on the PIN code entry
system distinctions and the H mode lock
setting when the meter is started.
During the meter start procedure, the H mode
lock setting is displayed so that it can be
G428ZZ132_
checked.
Caution:
• Once the meter has been started, the factory default status cannot be restored.
• This screen is not displayed after the meter has started.
(2) Demo mode
Demo mode allows material to be handled
while traveling before the hour meter is
started.
This screen shows the same H mode lock
setting as the meter start screen. This can be
checked when demo mode is set.
G428ZZ133_
While demo mode is selected, “DEMO” is

displayed on the key on hour meter screen.
G428ZZ134_
Caution:
• The demo mode screen is not displayed after the meter has started.
• For information on the vehicle status in demo mode, refer to "Notes on Delivery".
(3) Secondary password for service

Where it is deemed necessary by service staff, you can set a secondary password to protect the
service functions.
This prevents the operator from mistakenly accessing the service functions.
Once this setting has been configured, the secondary password must be entered to use the
service functions.
Only someone who knows the specified password can cancel the secondary password.
Caution:
• A secondary password should only be set when necessary.
• If the secondary password is lost, the multifunction display DX must be replaced.
• To ensure that the secondary password is lost and that access to the service functions is not
blocked, you should ensure that secondary passwords are managed systematically by the
dealership or retailer.
• If you sell or otherwise dispose of the vehicle and will no longer be managing it, you should
cancel the secondary password.
NMF-88
MATCHING
General
Each function is controlled by using the sensors and each signal voltage at standard vehicle condition stored in the
controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a sensor at standard
vehicle condition) is required when performing maintenance on a section or replacing parts related to the sensor.
For the accelerator sensor used for drive functions, the signal voltage values at accelerator fully released,
accelerator fully closed are stored, respectively, in the controller to control based on these values. When servicing
these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard
vehicle condition) is necessary.
For the tilt angle, load and tire angle sensors used for SAS-R functions, the signal voltage values at standard
vehicle condition are stored respectively, in the controller to control based on these values. When servicing or
replacing these sensors, matching (updating the sensor signal voltage value in the standard vehicle condition) is
necessary. Also, matching is needed for the tilt angle sensor when the vehicle posture has changed excessively,
and for the load sensor when the load under no load condition (no load on fork) is changed because of addition or
removal of any attachment or fork, replacement of mast or change of fork length. On the other hand, matching is
needed for the tire angle sensor when the tire angle sensor or related part is replaced.
Each lever angle sensor for load-handling lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment. When servicing these sensors or replacing
related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary.
It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire
size or type is changed according to “TIRE DATA List”.
Matching Items and Prerequisite for Implementation

1. DRIVE
Prerequisite for
No. Indication Description
implementation
Accelerator sensor output value with fully opened accelerator
1 ACCEL OFF *1,*3
position to the controller.
ACCEL FWD Accelerator sensor output with the accelerator lever tilted fully
2 *1,*3
END forward
ACCEL BWD Accelerator sensor output with the accelerator lever tilted fully
3 *1,*3
END back
2. SAS-R
Prerequisite for
implementation
Tire angle sensor output value with the tire in the straight
1 TIRE CENTER *2,*4
travel position
Tire angle sensor output value with the tire turned fully to the
2 TIRE RIGHT END *2,*4
right
Tire angle sensor output value with the tire turned fully to the
3 TIRE LEFT END *2,*4
left
STEERING Steering torque sensor output value when steering is not
4 *2,*5
CENTER being used
5 SPEED DATA Speed sensor output value *2,*6
For No.5, "SPEED DATA", automatic matching is performed when the vehicle satisfies the given
conditions (vehicle standard state). You can check the matching results in the "SPEED DATA" screen.
NMF-89
3. LOAD METER
Prerequisite for
implementation
The mast type is stored.
1 MAST TYPE *7,*10
VJSVJFSVJFVJFSWJFWJQFVJ“ - ” (N/A)
2 CYL. SIZE 1 Diameter of the lift cylinder is stored. *7,*10
3 CYL. SIZE 2 Diameter of the lift cylinder is stored. *7,*10
4 ZERO SET 1 Zero point of the load meter is stored. *7,*8,*9,*10
5 ZERO SET 2 Zero point of the load meter is stored. *7,*8,*9,*10
As requested
by customer to
6 COMPENSATION The value of load meter compensation data is stored.
adjust the
accuracy
4. TIRE DATA
Prerequisite for
implementation
1 TIRE DATA The tire data according to the tire size is stored. *1,*6
Prerequisite content for implementation

*1: When main controller replacement
*2: When replacing the EPS controller
*3: When removing/installing or replacing the accelerator sensor
*4: When removing/installing or replacing tire angle sensor
*5: When removing/installing or replacing the steering torque sensor
*6: When replacing a load tire or drive tire
*7: When removing/installing or replacing mast
*8: When removing/installing or replacing load sensor
*9: When installing or changing attachment or fork
*10: When replacing the multifunction display DX
NMF-90
NMF-91
PIN CODE ENTRY SYSTEM
Page
General ............................................................ NMF-92
Basic specifications ....................................... NMF-92 0
PIN for operators .............................................. NMF-92
Initial PIN ......................................................... NMF-92 1
Profile ............................................................. NMF-93
System configuration ..................................... NMF-94 2
Name and feature of each component .......... NMF-95
Name of each component ................................. NMF-95
3
Feature of each component .............................. NMF-95
4
Basic operations ............................................. NMF-96
Login operation ................................................ NMF-96 5
Logoff operation .............................................. NMF-96
Protection from password attacks ..................... NMF-97 6
Operation on factory setting ............................. NMF-97
Inspection of enabling the login ................... NMF-97 7
Inspection of disabling the login .................. NMF-97
Setting functions ............................................ NMF-98 8
Introductions ................................................... NMF-98
Registry of PINs for operators ........................... NMF-99 9
Change of assigned profile ............................... NMF-100
Delete of PINs for operators .............................. NMF-102 10
Delete of a selected PIN .............................. NMF-102
Delete all PINs ............................................ NMF-103 11
Profile setting .................................................. NMF-104
Selecting a profile number to edit ................ NMF-104
12
Power control setting .................................. NMF-105
Travel setting ............................................. NMF-106
13
Change of initial PIN ......................................... NMF-109
Setting of log-off time ....................................... NMF-110
14
Demo mode ..................................................... NMF-110
15
16
17
18
19
NMF-92

General
At this model change, the “PIN Code Entry System” with ten-key pad has been developed and set as an
option.
Only operators who have registered PINs (Personal Identification Number) can activate the vehicle with
this feature. This can contribute to avoidance of irregular use by unauthorized persons.
This system has ten different vehicle settings called “PROFILE” and each PIN can be assigned to one
profile out of these ten profiles.
Administrators can use this feature to limit various vehicle performances for safety management and to
fit the vehicle settings to each operator’s favorites.
The degree of protection provided by enclosures (IP code) of the ten-key pad is equivalent to IP55.
Caution:
This system is not an antitheft system.
Ten-key pad G428ZZ028_
Basic specifications
1. PIN for operators
Maximum 100 PINs can be registered.
PIN consists of 4 to 8 digits.
(Ex. The system distinguishes “30588” as different code from “030588”.)
2. Initial PIN
The system has one non-erasable “Initial PIN” for emergency.
The default initial PIN is “99999999” and can be changed to any PINs with 8 digits.
To keep using the initial PIN as “99999999” is not recommended for security reasons. The
administrator should change it and need to manage new number not to forget it.
If the initial PIN gets unknown, nobody can login in the worst case.
Please note that the same PIN as the initial PIN or “99999999” cannot be registered as the PINs for
operators.
NMF-93
3. Profile
• Administrator can register ten profiles (#0 to #9) about the vehicle settings.
• And each registered PIN can be assigned to one profile out of ten profiles.
• Items that can be set in each profile, and the differences from the models without this option are
shown in the following table.
No. Item Models with PIN Code Entry System Models without PIN Code Entry System
A vehicle has only one setting value.
Each profile has the setting value
Power Selectable from among H, P, S, E and
respectively.
1 control Original modes.
Administrators can change this on the
setting Operators can change this on the power
profile settings menu.
control menu.
Low-speed respectively.
2 Operators can change this on the
setting Administrators can change this on the
operator’s menu.
Maximum A vehicle has only one setting value.
respectively.
3 speed Administrators can change this on the
limiter administrator’s menu.
Overspeed respectively.
4 Operators can change this on the
alarm Administrators can change this on the
operator’s menu.
A vehicle has a set of various tuning
parameters.
Service technicians can change this on A vehicle has a set of various tuning
the masked menu. parameters.
5 Tuning
Moreover, each profile has certain The setting can be changed using the
tuning parameters respectively. service menu of the service function.
administrator’s menu.
• Because tuning items that can be set in the profiles have been extracted from the vehicle tuning
parameters of the masked menu, both tuning parameters can tune same characteristics of the vehicle.
• But the tuning ranges in the profile are limited in a certain range at the center of their base tuning
parameters as follows.
Example
Speed
TUNING No.7 of vehicle
Strong
TUNING No.9 of vehicle
Weak
Weak Strong
Accel ON Accel OFF Time
TUNING No.D-01 of profile TUNING No.D-02 of profile G428ZZ029_

NMF-94
• When a base vehicle tuning item is changed, the vehicle characteristics will change even under the
same profile setting because tuning items in the profile are originated at the center of the base vehicle
tuning.
• Tuning items in the profile and relations with their base vehicle tuning items are shown in the following
table.
• Please refer to “Tuning function” of “Masked function” in chapter “MULTI FUNCTION DISPLAY DX” for
detail about each tuning item.
Level (*: Default setting) Based vehicle

Menu No. Item
1 2 3 4 5 6 7 8 tuning item
D-01 Acceleration torque Weak * Strong Tuning No.7

Regenerative braking torque at
D-02 Weak * Strong Tuning No.9
DRIVE accelerator off
TUNE Acceleration and regenerative Tuning
D-03 Weak * Strong
braking torque at switch-back No.11, No.13
D-04 Not used * -
System configuration
Certification of PIN
PIN entry assignment of profile number
Ten-key Multifunction display DX
CAN-BUS
Main controller
Key-on management
vehicle setting corresponding to profile No.
G428ZZ030_
NMF-95
Name and feature of each component

1. Name of each component
3
1 2
G428ZZ031_
No. Name No. Name

1 Ten-key 3 Main controller
2 Multifunction display DX
2. Feature of each component
No. Name Feature

This ten-key installed on the instrumental panel is used for enter the
1 Ten-key
PIN, login and logoff.
Multifunction display DX judges if the entered PIN is certificated by
searching the registered PINs on its memory.
When the entered PIN has been registered, the multifunction display
DX sends the assigned profile number of the PIN to the main
2 Multifunction display DX
controller.
By using this multifunction display DX, administrators can register the
PINs, delete them, assign the profile number to each PIN, or set the
vehicle settings of each profile.
Main controller manages “KEY-ON” of the vehicle corresponding to
“LOGIN/LOGOFF” judgment by the multifunction display DX.
3 Main controller
The controller loads the vehicle setting data of the instructed profile
number, and changes the behavior of the vehicle.
NMF-96
Basic operations
1. Login operation
• The ten-key waits any inputs with both red LED and green LED off when the vehicle is not
activating.
• The operator has to enter the PIN and press the login switch to activate the vehicle. When any
numeric key is pressed, the green LED will light and the buzzer will sound briefly according to this
key operation. So the operator can confirm the response of pressing button.
• The system checks PIN input to the registered PINs after pressing the login switch.
• If the entered PIN is certificated, the buzzer sounds like pipi (OK), and the green LED lights on and
the vehicle is activated. If the key switch has been already turned on at PIN certification, the green
LED lights on and the vehicle is activated. When the key is turned off, the system waits for the key
switch to be turned on for 10 seconds with the green LED blinked. After 10 seconds passed
without the key switch turned on, the certification is canceled and the LED lights off.
• When the vehicle is activated, the profile assigned by the PIN is loaded and the vehicle works
under its settings.
• If the entered PIN is not certificated, the buzzer sounds like pipiiiiiiii (NG), the system returns to the
logoff state.
Red LED Green LED
Ten-key pad
Logoff switch Login switch

G428ZZ032_
Caution:
• Pressing the logoff switch before completion of PIN input can make the entered numbers clear
and return to the logoff state.
• When the login switch is pressed after 9 digits or more are entered, the system never
certificates the PIN.
• If there is no key input for over 10 seconds after last input, the entered numbers are cleared
and the system returns to logoff state.
2. Logoff operation
• The operator can turn off the vehicle by pressing the logoff switch when the vehicle activates. At
that time, the system turns off the green LED, lights the red LED for one second, and the buzzer
sounds briefly.
• Without any operations, when the timer of “Auto Power Off” is out, the system returns to key-off
state automatically.
• Only turning off the key switch without pressing the logoff switch can shift to key-on waiting mode.
In this mode, the green LED blinks and the operator can activate the vehicle again without PIN
input only by turning on the key switch before the waiting time is out.
• This waiting time can be set to 0, 5, 10 or 15 minutes in the administrator’s menu on the
multifunction display DX (Default = 0 second).
NMF-97
3. Protection from password attacks

• The system has a protective function from the password attacks.
• This function works depending on counts of consecutive wrong PIN inputs as follows.
Count of wrong PIN input Motion
The buzzer sounds and the red LED lights for 1 second. New PIN input is
1-4
prohibited during this period.
The buzzer sounds and the red LED lights for 5 seconds. New PIN input is
5-10
The buzzer sounds and the red LED lights for 1 minute. New PIN input is
11-20
• After the counts have reached to 20, the system goes into the lock-mode.
• The green and red LEDs blink simultaneously and the buzzer sounds like piiii-piiii for 5 seconds if
an operator enters any PIN on this mode.
• Only entering the initial PIN can be certificated and reset this mode. (Disconnecting the battery
also can reset it.)
• Before the system has transferred itself to the lock-mode, it resets the counts to enter wrong PINs
when a correct PIN for operators is entered.
Caution:
The counts to enter wrong PINs do not increase by pushing the logoff switch before completing
entering a PIN.
4. Operation on factory setting
• Only pressing the login switch can activate the vehicle with the factory setting.
• This condition is prepared for the efficient and easy login until the vehicle is delivered to customers.
• The factory setting will be disabled once the “Hour meter start” is done when the vehicle is
delivered to customers.
• There are two preset PINs prepared for the inspection of the PIN code entry system. The operation
of this system can be inspected by using these two PINs on the factory setting as follows.
(1) Inspection of enabling the login
• Entering “12345” or “67890” and pressing the login switch can activate the vehicle because
these two PINs have been registered on factory setting.
• Both PINs enable the inspection of the numeric switch recognition as well as the operation of
certification.
(2) Inspection of disabling the login
• If the login switch is pressed after entering a PIN other than the above PINs and “99999999”,
the vehicle never activates even on this factory setting.
• This is an inspection for the disabling operation of this system.
Caution:
The system cannot be returned to the factory setting once the “Hour meter start” has done.
NMF-98
Setting functions
1. Introductions
• Only the administrator can use the setting menu for “PIN code entry” built in the multifunction
display DX by entering the administrator password into it after login.
• Please refer to the chapter of the multifunction display DX for details about the administrator
password.
Caution:
On the model with PIN code entry system, the power control setting screen and the setting
screen for drive function are moved into the profile setting menu. So the initial administrator’s
screen differs as follows.
Initial administrator’s screen with

PIN code entry system
The power control setting screen and the setting screen for drive
function are moved into the profile setting menu when PIN code
entry system is installed.
Standard model
(without PIN code entry system)
G428ZZ200_
NMF-99
2. Registry of PINs for operators

• The administrator can register the new PINs for operators on the menu “REGISTRY”.
• This screen is displayed by selecting the menu “REGISTRY” by using switch (1) and switch (4) on
the menu for PIN code entry.
The number of registered PINs

G428ZZ201_
• The new PIN can be registered by continuing to press switch (1) “SET” for 2 seconds after entering
it by using ten-key. While entering a PIN, switch (2) can be used as “Back space”.
• Next, the screen waits to select the profile number to be assigned for the PIN. It can be selected by
using the ten-key or by using switch (2) and switch (3).
• Finally, the system will complete assigning the profile number to the PIN to press switch (1) “SET”
for 2 seconds.
Back space key can help correct the PIN. The number of registered PINs increases.

Profile number to the
Switch (2) Switch (3) assigned
G428ZZ202_
NMF-100
• After a registration of a new PIN has been completed, pressing the switch (1), “ADD” shifts the
screen to the registry screen again. Then, the administrator can continue to register PINs.
• If switch (4) is pressed, the screen returns to the menu screen.
Return to menu
G428ZZ203_
3. Change of assigned profile

• The administrator can change the assignment of the profile number to registered PINs on the
menu, “PROFILE CHANGE”.
• This screen is displayed by selecting the menu, “PROFILE CHANGE” by using switch (1) and
switch (4) on the menu for PIN code entry.
Assigned profile
Switch (1) Switch (4) Registered PINs

G428ZZ204_
NMF-101
• The PIN to change the assignment of the profile number can be selected by using switch (1). Here,
by entering the PIN with the ten-key directly, the administrator can narrow down the candidates out
of PINs and select a PIN.
• After the PIN selection, the screen changes to the profile assignment screen by pressing switch (4).
• The profile number can be changed by using the ten-key or by using switch (2) and (3). Finally, the
system will complete assigning the profile number to the PIN by pressing switch (1), “SET” for 2
seconds.
Back space key can help correct PIN.
G428ZZ205_
NMF-102
4. Delete of PINs for operators

• Administrator can delete any registered PINs for operators on the menu, “DELETE” except initial
PIN.
• This screen is displayed by selecting the menu, “DELETE” by using switch (1) and switch (4) on
(1) Delete of a selected PIN
• A PIN to be deleted can be selected by using switch (1). Here, by entering the PIN with the
ten-key directly, the administrator can narrow down the candidates of PINs and select the PIN
to be deleted.
• After the PIN selection, the screen changes to the waiting screen to delete by pressing switch
(4).
• Finally, the system will delete the selected PIN by pressing switch (1) “CLR” for 2 seconds.
The number of the registered

PIN decreases.
Back space key can help correct PIN.
G428ZZ206_
NMF-103
(2) Delete all PINs

• All PINs for operators except initial PIN can be deleted on the “DELETE” screen at one time.
• Pressing switch (4) after selection of “ALL CLEAR” by using switch (1) changes the screen to
the waiting screen to delete all PINs.
• The system will delete the all PINs except initial PIN by pressing switch (1), “CLR” for 2
seconds on the screen.
Deleting all PINs makes the number of the registered PIN become 0.
G428ZZ207_
NMF-104
5. Profile setting
• Administrator can set various parameters of each profile on the menu, “PROFILE SETTING”.
• This screen is displayed by selecting the menu, “PROFILE SETTING” by using switch (1) and
switch (4) on the menu for PIN code entry.
(1) Selecting a profile number to edit
• A profile number to edit can be selected by using switch (2) and switch (3) on the menu,
“PROFILE SETTING”.
• After selecting a profile number to edit, the screen changes to the profile edit menu screen by
pressing switch (1).
• Pressing switch (4) before pressing switch (1) returns the screen to the setting menu for “PIN
code entry”.
Profile number to edit
G428ZZ208_
NMF-105
(2) Power control setting

• The administrator can edit the power control setting of the selected profile number.
• The power control setting menu is the initial screen after selecting the profile number to edit.
After the other screen is changed into, pressing switch (2) and switch (3) can select it.
Caution:
H mode cannot be selected in any of the following three power control settings when “H mode
lock” is set to “YES”.
Power mode:
• The initial power mode after login can be set out of E, S, P, H and the original mode.
• This power mode screen is displayed by selecting the menu, “POWER MODE” by using
switch (1) and switch (4).
• Pressing switch (2) and switch (3) can change the power mode.
• When the original mode is selected, all of E, S, P, and H are highlighted.
• Though the initial power mode is selected by this setting, operators can change the power
mode during the operation.
• If the administrator wants to prohibit operators from changing the power mode, “menu-lock”
of the multifunction display DX is useful.
• When the “menu-lock” is effective, operators cannot change the power mode from the initial
mode after login. Please refer to the chapter of Multifunction display DX about “menu-lock”.
G428ZZ209_
Drive power control:

• The drive power in the original mode can be set up from five levels.
• The screen is displayed by selecting the menu, “DRIVE POWER” by using switch (1) and
switch (4).
• Pressing switch (2) and switch (3) can change the drive power.
G428ZZ210_
NMF-106
Lift power control:

• The lift power of the original mode can be set up from five levels.
• The screen is displayed by selecting the menu, “LIFT POWER” by using switch (1) and
switch (4).
• Pressing switch (2) and switch (3) can change the lift power.
G428ZZ211_
(3) Travel setting

• The administrator can edit the travel setting for each selected profile number.
• The travel setting menu screen can be selected by using switch (2) and switch (3) after the
profile number selected.
Low-speed setting:
• The limit speed while the low-speed setting function is effective can be changed.
• On models without PIN code entry system, operators can also change this value on the
operator’s menu.
• On models with PIN code entry System, this can be set only in this menu.
• When the menu lock is disabled, operators can change the motion of this function by using
switch (1).
• The screen is displayed by selecting the menu, “LOW SPEED” by using switch (1) and
switch (4).
• Pressing switch (2) decreases the limit speed and pressing switch (3) increases it.
• The adjustable range of this setting is from 2 to 20 km/h by 1 km/h.
G428ZZ212_
NMF-107
Maximum speed limiter:

• The limit speed of the maximum speed limiter can be changed in this setting.
• On both models with and without PIN code entry system, only administrator can set it up.
• The screen is displayed by selecting the menu, “SPEED LIMIT” by using switch (1) and
switch (4).
• Pressing switch (2) decreases the limit speed, and pressing switch (3) increases it.
G428ZZ213_
Overspeed alarm:
• The speed to activate the over speed alarm function can be changed in this setting.
• On models without PIN code entry system, operators can change this on the operator’s
menu.
On models with PIN code entry system, this can be set only in this menu.
• When the menu lock is disabled, operators can change the motion of this function by using
switch (1).
• The screen is displayed by selecting the menu, “SPEED ALARM” by using switch (1) and
switch (4).
• Pressing switch (2) decreases the speed, and pressing switch (3) increases it.
G428ZZ214_
NMF-108
Tuning for drive function:

• Four items for drive function can be tuned.
• The screen is displayed by selecting the menu, “DRIVE TUNING” by using switch (1) and
switch (4).
• In the “DRIVE TUNING” screen, the tuning item can be selected by pressing switch (1).
• Pressing switch (2) decreases the tuning value of the selected item and pressing switch (3)
increases it.
Switch (1) Switch (2) Switch (4)
Switch (3)
G428ZZ215_
NMF-109
6. Change of initial PIN

• Administrator can change the non-erasable initial PIN for emergency on the menu, “INITIAL PIN”.
• This screen is displayed by selecting the menu, “INITIAL PIN” by using switch (1) and switch (4) on
• Using ten-key can enter a new PIN. While the PIN input, switch (2) can be used as “Back Space”.
• After 8 digits have been entered, “SET” is displayed above switch (1). Then pressing switch (1),
“SET” fixes the entered PIN and the screen displays reconfirmation message.
• Finally, pressing switch (1) “SET” for 2 seconds sets the new initial PIN. Pressing switch (4) can
cancel the initial PIN change before completing this set-up.
Switch (2)
Current initial PIN
Back Space key can help To cancel the initial PIN number setting, return to the menu
correct the PIN. by pressing switch (4) before saving the setting by holding
down switch (1) for 2 sec.
G428ZZ216_
NMF-110
7. Setting of log-off time

• When the vehicle is activated, it can be moved to key-on waiting mode by turning off the key switch
without pressing the logoff switch. If the key switch is turned on within the time set here, the vehicle
can be started without the need to enter the PIN number.
• This screen is displayed if “LOG OFF TIME” is selected with switches (1), (2) and (3) on the PIN
code entry menu screen, and then switch (4) is pressed.
• This logoff time can be set to 0, 5, 10 or 15 seconds (Default = 0 second).
G428ZZ217_
8. Demo mode
• Until the vehicle is delivered to customers and the “Hour meter start” has been completed, all the
setting functions in the system have been disabled.
• If the temporary demonstration about all the functions of PIN code entry system is required,
“DEMO MODE” is recommended. This mode can be set up by the masked-function of the
multifunction display DX.
• All the registered PIN and profile data during “DEMO MODE” are remaining in the system memory
even if the “DEMO MODE” returns to ineffective with setting “NO”.
• Therefore they will be made effective again after “Hour meter start” is performed, or when “DEMO
MODE” is made effective again.
00E_general.book 1 ページ２０１２年７月６日金曜日午後３時１７分
0-1
GENERAL
Page Page
EXTERIOR VIEW ........................0-2 LUBRICATION CHART ............0-20 NMF
VEHICLE MODELS.....................0-3 PERIODIC REPLACEMENT 0
FRAME NUMBER .......................0-3 OF PARTS AND 1
LUBRICANTS .........................0-22
HOW TO USE
PERIODIC MAINTENANCE .....0-23
2
THIS MANUAL..........................0-4
INSPECTION METHOD ..............0-23 3
EXPLANATION METHOD .............0-4
TERMINOLOGY...........................0-5
NOTES ON DELIVERY ...............0-28 4
ABBREVIATIONS ........................0-5 5
OPERATIONAL TIPS..................0-6 6
JACKING UP...............................0-8 7
HOISTING THE VEHICLE .............0-9 8
TOWING THE VEHICLE..............0-10
9
CIRCUIT TESTER ...................... 0-11
10
STANDARD BOLT & NUT
TIGHTENING TORQUE ..........0-12 11
BOLT STRENGTH CLASS 12
IDENTIFICATION METHOD ......0-12
13
PRECOAT BOLTS ....................0-15
HIGH PRESSURE
14
HOSE FITTING 15
TIGHTENING TORQUE ..........0-15
16
WIRE ROPE SUSPENSION
ANGLE LIST ...........................0-16 17
SAFE LOAD FOR EACH WIRE 18
ROPE SUSPENSION ANGLE ...0-16
19
MEMBER WEIGHT LIST ..........0-17
RECOMMENDED LUBRICANT 20
QUANTITY AND TYPES.........0-18 21
0-2
EXTERIOR VIEW
G42800DA002_
0-3
VEHICLE MODELS
Battery STD Lifting height set for each mast
mast
Control Quan- standard
Model Volt- lifting
method tity V SV FV FSV
age height
(AH/ (mm (in)) (mm (in)) (mm (in)) (mm (in))
(V)
5HR) (mm NMF
(in))
7FBR10
Micro
computer
48 201
3000
(118.1)
2500 to 5000
(98.4 to 196.9)
2500 to 5000
(98.4 to 196.9)
2500 to 4000
(98.4 to 157.5)
3700 to 6000
(145.7 to 236.2)
0
7FBR
7FBR13
Micro
computer
48 201
3000
(118.1)
2500 to 5000
(98.4 to 196.9)
2500 to 5000
(98.4 to 196.9)
2500 to 4000
(98.4 to 157.5)
3700 to 6000
(145.7 to 236.2)
1
series
7FBR15
Micro
computer
48 280
3000
(118.1)
2500 to 5000
(98.4 to 196.9)
2500 to 5000
(98.4 to 196.9)
2500 to 4000
(98.4 to 157.5)
3700 to 6000
(145.7 to 236.2) 2
Micro- 3000 2500 to 5000 2500 to 5000 2500 to 4000 3700 to 6000
7FBR18
computer
48 280
(118.1) (98.4 to 196.9) (98.4 to 196.9) (98.4 to 157.5) (145.7 to 236.2) 3
FRAME NUMBER 4
Payload (ton)
Vehicle
Punching format Punching position 5
model
6
1.0 7FBR10 7FBR10-50011 7
8
9
1.25 7FBR13 7FBR13-50011
10
11
1.5 7FBR15 7FBR15-50011
12
13
14
1.8 7FBR18 7FBR18-50011
Frame No. punching position
15
16
17
18
19
20
21
0-4
HOW TO USE THIS MANUAL

EXPLANATION METHOD
Example
DISASSEMBLY•INSPECTION•REASSEMBLY
Tightening torque unit T = N·m (kgf·cm) [ft·lbf]_
• Some step numbers may be 4

1
omitted in some illustrations. 2
3
5 6
T = 46.1 to 48.1
(470 to 490)
[34.0 to 35.5]
5
9 1
Disassembly Procedure
1 Remove the cover. [Point 1]
2 Remove the bushing. [Point 2] Operation to be explained in following pages.
3 Remove the gear.
Point Operations
Explanation of operation point with illustration.
[Point 1]
Disassembly:
Make match marks before removing the pump cover.
[Point 2]
Inspection:
Measure the bushing inside diameter.
Inspection:Limit: 19.12 mm (0.752 in)
0-5
1. How to read component figures

(1) The component figures use the illustration in the parts
catalog for the vehicle model. Please refer to the (Example)
catalog to check the part name.
3201
Parts catalog
2. Matters omitted from this manual FIG number NMF
(1) This manual omits descriptions of the following jobs,
but perform them in actual operation: 0
(a) Cleaning and washing of removed parts as required
1
(b) Visual inspection (partially described)
2
TERMINOLOGY 3
Caution: 4
Important matters, negligence of which may cause accidents. Be sure to observe them.
Note:
5
Important items, negligence of which may cause accidents, or matters in operating procedure
which require special attention.
6
Standard: Value showing the allowable range in inspection or adjustment. 7
Limit: The maximum or minimum value allowed in inspection or adjustment. 8
9
ABBREVIATIONS
10
Abbreviation Meaning Abbreviation Meaning
ASSY Assembly SAE

Society of Automotive Engineers 11
(USA)
LH Left Hand SST Special Service Tool 12
LLC Long Life Coolant STD Standard
L/ Less TBC Traction and Brake Control
13
M/T Manual Transmission T/C Torque Converter & Transmission 14
OPT Option T= Tightening Torque
O/S Oversize {{T Number of Teeth ({{T) 15
PS Power Steering U/S Undersize
RH Right Hand W/ With (what follows is included)
16
17
18
19
20
21
0-6
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in
load capacity.
(3) Always turn the key switch OFF and disconnect the battery plug before the inspection,
maintenance or disassembly of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger,
oil pressure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the
parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packing and o-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.) If no tightening torque is specified,
tighten the bolt or nut according to the standard tightening torque table.
3. Protection of functional parts (Battery vehicle)
Thoroughly check each connector for any failure in or imperfect connection before reconnecting
the battery plug after the end of vehicle inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.
5. Disposal of waste fluid, etc.
When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or
scrapped without permission, it will either adversely affect human health or destroy the
environment. Always sort waste fluids, etc. and treat them properly by requesting disposal by
specialized companies.
6. Greasing up each part
In addition to periodic grease-up according to the lubrication chart, apply MP grease (or
molybdenum disulfide grease) to each sliding contact face when repairing a portion (like pedal
link) involving sliding contact.
0-7
7. Handling of electronic parts
(1) Never apply impacts to electronic parts such as a

microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be
deformed or be damaged due to static electricity.
G85700002_
8. Attention to high pressure oil
(1) Do not touch to the hydraulic hose / piping by bare

hand on inspection of oil leakage.
It is very dangerous if high pressure oil from pin hole
of hose / piping enters into the skin.
It is necessary to use a shield board together with
gloves and goggles to prevent high pressure oil
from directly hitting hands, face and so on.
Consult a doctor immediately if oil enters into the
skin, which may cause gangrene.
(2) Reduce residual pressure before disconnecting
G85700103_
hose / piping by operating material handling levers.
0-8
JACKING UP
Always observe the following instructions when jacking up the vehicle.
• When the fork is loaded, unload it and park the vehicle on a flat surface. Be sure to avoid an inclined
or rough surface.
• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at
any other point is dangerous.
• Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the
vehicle with the jack only is very dangerous.
• Never, under any circumstances, put any part of the body (including hands and feet) under the
jacked-up vehicle.
Jack-up point
Wooden stand points

0-9
HOISTING THE VEHICLE

When hoisting the vehicle, always observe the specified hoist attachment section and method. Never
hoist by any other attachment section as it is very dangerous.
0-10
TOWING THE VEHICLE

Tow the vehicle as follows in case of a failure or for loading onto a truck.
Note:
• As a rule, do not tow a reach type vehicle. If it is unavoidable, keep the towing distance within
the minimum required range.
• Use an eyebolt short enough that it will not touch the reach cylinder.
Spring washer
Plate washer (2 types) Nut
Shackle
Spring washer
Plate washer (2 types)
Eye Bolt (more M14)
Wire
40 mm (1.6 in)
Tractive long hole
14 mm (0.6 in)
60 mm (2.4 in)
26 mm (1.0 in)
Reach Cylinder G42800DA001_
0-11
CIRCUIT TESTER
Use a circuit tester that matches the object and purpose of measurement.
Analog type: This type is convenient for observing movement during operation and the operating
condition. The measured value should be used only for reference or rough judgement.
Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or
movement.
Difference between results of measurement with analog and digital types

*The results of measurements using the analog type and the digital type may be different.
Use the circuit tester according to its instruction manual.
Differences between the polarities of the analog type and the digital type are described below.
(1) Analog circuit tester
Forward Reverse Example of measurement result

Tester range: kΩ range
Black
Black Red Red
tester tester tester
tester Forward direction: Continuity 11 kΩ
probe
probe probe probe Reverse direction: No continuity ∞
(2) Digital circuit tester
Example of measurement result

Forward Reverse
Tester range: 2 MΩ range
Forward direction: Continuity 2 MΩ

Red Black Black Red Reverse direction: No continuity 1
tester tester tester tester
probe probe probe probe
0-12
STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. For tightening torque of hexagon head bolt, welded bolt and stud bolt with the standard bearing
surface, identify bolt class based on the below chart and then determine using the tightening torque
table.
2. For tightening torque of hexagon flange bolts, identify bolt class based on the below chart and then
determine using the tightening torque table.
3. For tightening torque of nuts, check the mating bolt and use the method 1.
BOLT STRENGTH CLASS IDENTIFICATION METHOD

Identification by Bolt Shape
Shape and class Class
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon head bolt

Two protruding lines 5T
Three protruding lines 7T
Four protruding lines 8T
Welded bolt 4T
No mark 4T
Stud bolt
Grooved 6T
0-13
Identification by Part No.

Part No. Shape
Length (mm) Diameter

Hexagon head bolt
Diameter (mm)
Length
Class
Diameter
Length (mm)
Stud bolt
Diameter (mm)
Length
Class
Tightening Torque Table
Diameter Pitch Specified torque

Class
mm (in) mm (in) N·m kgf·cm ft·lbf
6 (0.24) 1.0 (0.04) 5.4 55 4
8 (0.31) 1.25 (0.05) 13 130 9
10 (0.39) 1.25 (0.05) 25 260 19
4T
12 (0.47) 1.25 (0.05) 47 480 35
14 (0.55) 1.5 (0.06) 75 760 55
16 (0.63) 1.5 (0.06) 113 1150 83
6 (0.24) 1.0 (0.04) 6.5 65 5
8 (0.31) 1.25 (0.05) 16 160 12
10 (0.39) 1.25 (0.05) 32 330 24
5T
12 (0.47) 1.25 (0.05) 59 600 43
14 (0.55) 1.5 (0.06) 91 930 67
16 (0.63) 1.5 (0.06) 137 1400 101
6 (0.24) 1.0 (0.04) 7.8 80 6
8 (0.31) 1.25 (0.05) 19 190 14
10 (0.39) 1.25 (0.05) 39 400 29
6T
12 (0.47) 1.25 (0.05) 72 730 53
14 (0.55) 1.5 (0.06) 108 1100 80
16 (0.63) 1.5 (0.06) 172 1750 127
6 (0.24) 1.0 (0.04) 11 110 8
8 (0.31) 1.25 (0.05) 25 260 19
10 (0.39) 1.25 (0.05) 52 530 38
7T
12 (0.47) 1.25 (0.05) 95 970 70
14 (0.55) 1.5 (0.06) 147 1500 108
16 (0.63) 1.5 (0.06) 226 2300 166
6 (0.24) 1.0 (0.04) 12 120 9
8 (0.31) 1.25 (0.05) 29 300 22
10 (0.39) 1.25 (0.05) 61 620 45
8T
12 (0.47) 1.25 (0.05) 108 1100 80
14 (0.55) 1.5 (0.06) 172 1750 127
16 (0.63) 1.5 (0.06) 265 2700 195
0-14
Identification by Bolt Shape (Hexagon Flange Bolt)

Class 4.8T 6.8T 8.8T 10.9T 11.9T
No mark
Hexagon flange bolt
— —
No mark
Tightening Torque Table (Hexagon Flange Bolt)
Diameter Pitch Specified torque

Class
mm (in) mm (in) N·m kgf·cm ft·lbf
6 (0.24) 1.0 (0.04) 5.5 56 4
8 (0.31) 1.25 (0.05) 13 130 9
10 (0.39) 1.25 (0.05) 27 280 20
4.8T
12 (0.47) 1.25 (0.05) 50 510 37
14 (0.55) 1.5 (0.06) 78 800 58
16 (0.63) 1.5 (0.06) 120 1220 88
6 (0.24) 1.0 (0.04) 7.5 80 6
8 (0.31) 1.25 (0.05) 19 190 14
10 (0.39) 1.25 (0.05) 39 400 29
6.8T
12 (0.47) 1.25 (0.05) 71 720 52
14 (0.55) 1.5 (0.06) 110 1120 81
16 (0.63) 1.5 (0.06) 170 1730 125
6 (0.24) 1.0 (0.04) 12 120 9
8 (0.31) 1.25 (0.05) 29 300 22
10 (0.39) 1.25 (0.05) 61 620 45
8.8T
12 (0.47) 1.25 (0.05) 110 1120 81
14 (0.55) 1.5 (0.06) 175 1780 129
16 (0.63) 1.5 (0.06) 270 2750 199
6 (0.24) 1.0 (0.04) 15.5 160 12
8 (0.31) 1.25 (0.05) 38 390 28
10 (0.39) 1.25 (0.05) 80 820 59
10.9T
12 (0.47) 1.25 (0.05) 145 1480 107
14 (0.55) 1.5 (0.06) 230 2350 170
16 (0.63) 1.5 (0.06) 360 3670 266
6 (0.24) 1.0 (0.04) 17.5 180 13
8 (0.31) 1.25 (0.05) 42 430 31
10 (0.39) 1.25 (0.05) 89 910 66
11.9T
12 (0.47) 1.25 (0.05) 160 1630 118
14 (0.55) 1.5 (0.06) 260 2650 192
16 (0.63) 1.5 (0.06) 400 4080 295
0-15
PRECOAT BOLTS
(Bolts with Seal Lock Agent Coating on Threads)
1. Do not use the precoat bolt as it is in either of the

following cases.
(1) After it is removed.
(2) When the precoat bolt is moved (loosened or
Seal lock agent tightened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable
tightening torque range. If the bolt moves, retighten it
according to the steps below.
2. Method for reuse of precoat bolts.

(1) Wash the bolt and threaded hole. (The threaded
hole must be washed even for replacement of the
bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact
surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque N·m (kgf·cm) [ft·lbf] Hose inside
of screw Standard Tightening range diameter mm (in)
7/16 – 20UNF 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
9/16 – 18UNF 34 (350) [25.3] 32 to 36 (330 to 370) [29.3 to 26.8] 9 (0.35)
3/4 – 16UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8 – 14UNF 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
7/8 – 14UNF 78 (800) [57.9] 74 to 82 (740 to 840) [53.5 to 60.8] 15 (0.59)
1·1/16 – 12UNF 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
130 to 144 (1330 to 1470)
1·5/16 – 12UNF 137 (1400) [101.3] 25 (0.98)
[96.2 to 106.4]
PF1/4 25 (250) [18.1] 24 to 26 (240 to 270) [17.4 to 19.5] 6 (0.24)
PF3/8 34 (350) [25.3] 32 to 36 (330 to 370) [23.9 to 26.8] 9 (0.35)
PF1/2 59 (600) [43.4] 56 to 62 (570 to 630) [41.2 to 45.6] 12 (0.47)
PF3/4 118 (1200) [86.8] 112 to 123 (1140 to 1250) [82.5 to 90.4] 19 (0.75)
130 to 144 (1330 to 1470)
PF1 137 (1400) [101.3] 25 (0.98)
[96.2 to 106.4]
0-16
WIRE ROPE SUSPENSION ANGLE LIST

Suspen- Suspen-
Compres- Suspension Compres- Suspension
sion Tension sion Tension
sion method sion method
angle angle
1.00 1.41
0° 0 time 90° 1.00 time
time time 90°
1 tf
tf
41
1.
2t 2t
30°
1.04 2.00
30° 0.27 time 120° 1.73 time
time time 120°
tf
tf
1.04
2
2t 2t
1.16 60°
60° 0.58 time
time
6 tf
2t
1.1
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

Unit: N (ton: tf) [lbf]
Rope Single-rope
Cutting Two-rope suspension Four-rope suspension
diameter suspension
load
mm (in) 0° 0° 30° 60° 90° 0° 30° 60° 90°
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 (0.24) (2.18) (0.31) (0.62) (0.60) (0.53) (0.44) (1.24) (1.20) (1.06) (0.88)
[4810] [680] [1370] [1320] [1170] [970] [2730] [2650] [2340] [1940]
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 (0.31) (3.21) (0.45) (0.90) (0.87) (0.78) (0.64) (1.80) (1.74) (1.56) (1.28)
[7080] [990] [2000] [1920] [1720] [1410] [3970] [3840] [3440] [2820]
49230 6960 14020 13440 11770 9810 27460 26480 23540 19610
10 (0.39) (5.02) (0.71) (1.43) (1.38) (1.20) (1.00) (2.80) (2.70) (2.40) (2.00)
[11070] [1570] [3150] [3020] [2650] [2210] [6170] [6000] [5290] [4410]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5
(7.84) (1.12) (2.20) (2.10) (1.90) (1.50) (4.40) (4.20) (3.80) (3.00)
(0.49)
[17290] [2470] [4850] [4780] [4190] [3310] [9700] [9260] [8380] [6620]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 (0.55) (9.83) (1.40) (2.80) (2.70) (2.40) (1.90) (5.60) (5.40) (4.80) (3.80)
[21680] [3090] [6170] [6000] [5290] [4190] [12350] [11910] [10580] [8380]
0-17
MEMBER WEIGHT LIST

Unit: kg (lb)
Member Weight
7FBR10•13 391 (862)
Battery
7FBR15•18 514 (1133)
Drive motor 7FBR10-18 26 (57)
Pump motor 7FBR10-18 25 (55)
Drive unit W/drive wheel 7FBR10-18 90 (198)
7FBR10•13 350 (772)
Mast ASSY L/lift bracket & fork
7FBR15•18 360 (794)
7FBR10 2030 (4476)
7FBR13 2050 (4520)
Vehicle weight
7FBR15 2190 (4829)
7FBR18 2270 (5005)
0-18
RECOMMENDED LUBRICANT QUANTITY AND TYPES

Applicable portion Type Quantity
STD vehicle: Hypoid gear oil
SAE 85W-90
Approx. 2.0l
API GL-5
Drive unit (until overflow from oil filler port)
Cold storage vehicle: Hypoid gear oil
The above value is for reference.
SAE75W-80W
API GL-4
STD: Hydraulic oil ISO VG32
See the hydraulic oil filling
Hydraulic oil Cold area specification: Auto Fluid Special W
quantity below.
Cold storage vehicle: Mobil Aero HFE
Chassis parts See the greasing list on the next page.
Battery Distilled water Appropriate amount
Hydraulic Oil Filling Quantity

Unit: l (US gal)
Hydraulic oil filling
quantity 12 Tank
14 15 16 17 18 20 22 24 25 26
capacity
MAST
2500 to 3000 { 9 (2.38)
V, SV 3500 to 4000 { 11 (2.90)
4500 to 5000 { 12 (3.17)
2500 to 3000 { 9 (2.38)
7FBR series FV
3300 to 4000 { 11 (2.90)
3700 to 4000 { 11 (2.90)
FSV 4300 to 5000 { 12 (3.17)
5500 to 6000 { 13 (3.43)
0-19
Greasing List
Grease type
Application and greasing points
STD Cold storage vehicle
Drive motor output
Molywhite TA No. 1
coupling spline
Drive unit turning bearing Auto rex A grease Esso beacon 325
Steering gear tooth flanks Chassis grease special
Caster oscillation pin center bearing Chassis grease special Esso beacon 325
Caster wheel bearing MP grease Esso beacon 325
Steering torque sensor cam Esso beacon 325
Steering shaft spline Chassis grease special Esso beacon 325
Filling EPS gear case Chassis grease special Esso beacon 325
Disc brake shaft & cam sliding portion Chassis grease special Esso beacon 325
Brake link pin
Hermecoat TX168 Esso beacon 325
Brake arm pin
Brake spring adjusting pin MP grease
Suspension shaft bearing Chassis grease special Esso beacon 325
Suspension shaft spline Chassis grease special Esso beacon 325
Lock cylinder pin Chassis grease special Esso beacon 325
Side sliding battery stopper shaft MP grease
Inner mast free bar MP grease Esso beacon 325
Fork shaft Chassis grease special
Reach leg side face Chassis grease special Esso beacon 325
Inner mast rail (SV, lower 400 mm) MP grease Esso beacon 325
C/V lever link and shaft portions MP grease
Oil pump shaft spline Chassis grease special
Tilt pulley (V, SV)
MP grease
ATT pulley (V, SV)
Inside of tire angle sensor Esso beacon 325
0-20
LUBRICATION CHART
STD Vehicle
A 1
B 2
E 3
D D 4
E 5
E 6
10 E E 7
11 C C E 8
12 E E 9
Pre-operation check
Weekly (40 hrs) inspection
6 weeks (250 hrs) inspection
6-month (1000 hrs)

inspection
{: Inspection and addition 1. Mast strip* 11. Drive unit

z: Replacement 2. Lift chain* 12. Reach leg
(A) MP grease 3. Brake cam
(B) Motor oil
4. Hydraulic oil tank
(C) Hypoid gear oil
(SAE85W-90) 5. Steering shaft spline
(D) Hydraulic oil (ISO VG32) 6. Steering gear
(E) Chassis grease special 7. Suspension shaft
8. Caster shaft
(low overall height vehicle)
9. Caster shaft
10. Fork shaft *: Both sides
0-21
Cold Storage Vehicle
A 1
B 2
E 3
10 F D D 4
E 5
11 F E 6
12 E E 7
13 C C E 8
14 E E 9
15 E
16 E
Pre-operation check
Weekly (40 hrs) inspection
6 weeks (250 hrs) inspection
6-month (1000 hrs)

inspection
{: Inspection and addition 1. Mast strip* 14. Reach leg

z: Replacement 2. Lift chain* 15. Brake pedal
(A) MP grease 3. Brake cam 16. Reach cylinder
(B) Motor oil 4. Hydraulic oil tank
(C) Hypoid gear oil 5. Steering shaft spline
(SAE75W-80W) 6. Steering gear
(D) Cold area specification: 7. Suspension shaft
Auto fluid special W 8. Caster shaft
Cold storage vehicle: (low overall height vehicle)
Mobil Aero HFE 9. Caster shaft
(E) Esso beacon 325 10. Oil control valve limit
(F) NOK scluber ISOFLEX switch
TOPAS NB52 11. Brake limit switch
12. Fork shaft
13. Drive unit *: Both sides
0-22
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

z: Replacement
I:Inspection•Repair or replacement if required.
Replacement timing Every Every Every Every Every

week 6 weeks 3 months 6 months 12 months
Every Every Every Every Every
Item 40 hours 250 hours 500 hours 1,000 hours 2,000 hours
Drive unit oil l
Hydraulic oil l 
z New
Hydraulic oil filter vehicle initial l 
replacement
Wheel cylinder cup seals
l
(Front brake)
z Every
Hydraulic hose
2 years
z Every
Chain
3 years
z Every
Swing lock cylinder
10,000 hours
0-23
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection•Repair or replacement if required.
M: Measurement•Repair or adjustment if required.
T: Retightening C: Cleaning L: Lubrication
*1
: Flaw detector
Inspection Period Every

Every Every Every
12
6 weeks 3 months 6 months
months
Every Every
Every Every
1000 2000
Item 250 hours 500 hours
hours hours
ELECTRICAL SYSTEM
Rotation sound I   
Looseness in the connecting parts T   
Insulation resistance M  
Brush wear and sliding condition
Motor I 
(For Pump motor, PS motor)
Commutator contamination, damage
I 
(For pump motor, PS motor)
Brush, spring wear
M
(For pump motor, PS motor)
Charging level I   
Electrolyte level I   
Electrolyte specific gravity M   
Terminal looseness I   
Battery Abnormality in the upper portion of the
I   
battery case
Insulation resistance M  
Voltage measurement of each battery cell
M
after charging
Timer function I   
Terminal looseness I   
Charger HVR function voltage measurement M  
Operating condition of the magnetic switch,
I
contact contamination, roughness
Contact looseness, damage, abrasion I   
Operating condition of the auxiliary contact,
I   
contamination, abrasion
Magnet Mounting condition of the arc shooter I
contactor Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead
I
wire, looseness
Operating condition and timing I   
Microswitch
Damage and looseness of installing parts I   
0-24

Every Every Every
12
months
Every Every
Every Every
1000 2000
hours hours
Accelerator
Operation condition, damage I   
lever
Operation condition I   
Controller Interior contamination, damage C   
Motor input voltage M
Fuse Looseness I   
Harness deterioration, champ damage and
I   
Wiring looseness
(including Looseness in connecting parts, taping
I   
charging condition
cord) Connecting condition and damage of the
I   
battery connector
POWER TRANSFER SYSTEM
Oil leakage I   
Oil level I   
Drive unit Bolt or nut looseness T
Drive wheel shaft bearing abnormal sound
I   
and looseness
TRAVELING EQUIPMENT
Damage and deformation I
Suspension
Suspension shaft grease L   
Tire damage and abnormal wear I   
Load wheel bearing abnormal sound and
I   
Wheel looseness
Caster wheel bearing abnormal sound and
I   
looseness
STEERING SYSTEM
Steering Play and looseness I   
wheel Function I   
Power Sensor function I   
steering Looseness of mounting T   
Shaft and Loosening, looseness and damage I   
joint Coupling wear and installation state I   
BRAKING SYSTEM
Depressed pedal clearance from the floor
Brake M   
plate
pedal
Braking effect I   
Rod and Loosening, looseness and damage I   
cable Functioning status I   
0-25

Every Every Every
12
months
Every Every
Every Every
1000 2000
hours hours
Clearance between brake cam and adjust
M   
screw
Clearance between disc wheel and pad M   
Brake link lever operating status I
Disc brake Disc brake and disc wheel set bolt loose T
(Rear brake)
Disc brake wheel wear and damage I
Pad wear and damage I
Cam operating status, rusting I
Disc brake spring fatigue M
Brake pipe
Leak, damage and mounting condition I   
(Front brake)
Clearance between drum and lining M   
Wear of shoe sliding portion and lining I
Brake drum Drum wear and damage I
and brake
Shoe operating condition I
shoe
(Front brake) Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Wheel Function, wear, damage, leak and mounting
I
cylinder looseness
Backing plate Deformation, cracks and damage I

(Front brake) Loose mounting T
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I   
Forks Misalignment between left and right fork fingers I   
Cracks at fork root and welded part I*1
Deformation and damage of each part and
I   
crack at welded part
Mast and lift bracket looseness I   
Mast and lift Wear, damage and rotating condition of rollers I   
bracket
Wear and damage of roller pins I
Wear and damage of mast trip I   
Shaft type fork shaft grease L 
Tension, deformation and damage of chain I   
Chain lubrication I   
Chain and
chain wheel Abnormality of chain anchor bolt I   
Wear, damage and rotating condition of chain
I   
wheel
Various Abnormality and mounting condition of each
I   
attachments part
0-26

Every Every Every
12
months
Every Every
Every Every
1000 2000
hours hours
HYDRAULIC SYSTEM
Loosening and damage of cylinder mounting T   
Deformation and damage of rod, rod screw and
I   
rod end
Cylinder operation I   
Natural drop and natural forward tilt
M   
(hydraulic drift)
Cylinder
Oil leak and damage I   
Wear and damage of pin and cylinder bearing I   
Lifting speed M   
Reach speed I   
Uneven movement I   
Oil pump Oil leak and abnormal sound I   
Oil level and contamination I   
Hydraulic
Tank and oil strainer C 
oil tank
Oil leak I   
Control Loose linkage I   
lever Operation I   
Oil control
Relief pressure measurement M
valve
Relief valve and tilt lock valve functions I   
Hydraulic
Deformation and damage I   
piping
Loose joint T   
SAFETY DEVICES, ETC.
Cracks at welded portion I   
Head guard
Deformation and damage I   
Loosening of mounting T   
Back-rest
Deformation, crack and damage I   
Lighting
Function and mounting condition I   
system
Horn Function and mounting condition I   
Direction
indicator
Instruments Functions I   
Backup
buzzer
Rear-view Dirt, damage I   
mirror Rear reflection status I   
0-27

Every Every Every
12
months
Every Every
Every Every
1000 2000
hours hours
Damage and cracks of frame, cross
I
Body members, etc.
Bolt looseness T
Loosening and damage of mounting I   
Floor
Floor switch function I   
OPS Functions I   
Functions I   
Loosening and damage at sensor mounting
I   
portion
Damage, deformation, oil leakage and loos-
I   
ening of the mounting of functional parts
TBC Loosening and damage of wire harnesses I   
Lock cylinder accumulator performance I
Rusting and corrosion of load sensor I
Oil leakage of brake valve ASSY I 
Accumulator pressure M
Brake operating pressure M
Others Grease up L   
0-28
NOTES ON DELIVERY
Starting the Hour Meter
At shipment from the factory, the hour meter, range finder, trip meter and maintenance hour meter have not started
counting. Upon delivery, start the hour meter using the procedure described in the repair manual.
Before the hour meter is started, the limitations shown below apply.
Function Status
Basic functions All cargo handling is prohibited while the vehicle is running.
PIN code entry operates in the default factory setup mode.
The vehicle can be started simply by pressing the Login button, without
PIN code entry system
entering a PIN code.
All setup functions relating to PIN code entry are disabled.
For information on the optional functions above, refer to “PIN CODE ENTRY SYSTEM” on page NMF-92 in NEW
MODEL FEATURES.
Demo Mode
To temporarily set the functions to Demo mode, enable the vehicle's “DEMO MODE” in the Multifunction display DX
service functions. This cancels the above limitations and restores normal operation.
Note that all the PIN and profile data set or registered during “DEMO MODE” are retained even if demo mode is
cancelled.
01E_battery.book 1 ページ２０１２年７月６日金曜日午後４時６分
1-1
BATTERY
Page
BATTERY COMPARTMENT NMF
AND REQUIRED WEIGHT....................................1-2
0
SERVICE STANDARD ............................................1-2
1
TROUBLESHOOTING ............................................1-3
BATTERY ................................................................1-4
2
REMOVAL•INSTALLATION .......................................1-4 3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1-2
BATTERY COMPARTMENT AND REQUIRED WEIGHT

1
When the battery is to be purchased locally, always adjust the weight to satisfy the minimum required
weight as shown in the table below.
Compartment dimensions Minimum required Maximum
mm (in) battery weight battery weight Remarks
Depth X Width Y Height Z kg (lb) kg (lb)
1,007
7FBR10•13 266 (10.5) 570 (22.4) 350 (770) 385 (850)
(39.6)
7FBR15•18 1,007 465 (1030) 600 (1320)

376 (14.8) 570 (22.4)
(39.6)
h
pt
De
Height
Width
SERVICE STANDARD
Specific gravity upon full charge 1.280 [20 °C (68 °F)]
Specific gravity upon end of discharge 1.150 [20 °C (68 °F)]
Discharge end voltage 48 V 42.5 V
Electrolyte Refined dilute sulfuric acid
Electrolyte to be added Distilled (deionized) water
Insulation resistance 1 MΩ or more
1-3
TROUBLESHOOTING
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
1-4
BATTERY
REMOVAL•INSTALLATION
Always remove or install the battery in no-load state (without any load on the fork).
Removal Procedure
1 Fully depress the unlock pedal and maintain that state. [Point 1]
2 Operate the reach lever to push the mast W/battery out. [Point 2]
3 Disconnect the battery plug.
4 Remove the battery case W/battery. [Point 3]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
• Connect the battery electrolyte level / temperature sensor before connecting the battery plug.
• If you connect the battery plug before connecting the battery electrolyte level / temperature
sensor, an error may be displayed.
If the plug and sensor are connected correctly, the error display will go blank after about 1
minute.
1-5
Point Operations
[Point 1]
Removal:
While fully depressing the unlock pedal, take the battery
out.
NMF
0
1
[Point 2]
Removal: 2
Since the mast stops upon reaching a certain extent,
turn the ignition key to the position for battery removal 3
/ installation. While keeping the key in that position,
operate the reach lever again to push the battery out. 4
Installation:
Turn the ignition key to and hold at the position for
5
battery removal / installation, and operate the reach
lever to pull the battery in. 6
[Point 3] 7
Removal•Installation:
SST
SST 25009-13201-71 8
9
10
11
12
13
14
15
16
17
18
19
20
21
1-6
Take Out The Battery from The Side
Door stopper
Door
Battery
Battery stopper
Components of door stopper
Knob
Spring pin
Boss
Spring
Shaft
Components of battery stopper
Battery stopper Bush Boss Bush
Plate washer
Nut
G42801TA001_
1-7
Inspection
Stopper 1. Electrolyte level check

White line Open the cap. If the white line of the red float has
fallen, add distilled water.
Add water until the white line appears.
Stop water addition when the white line appears, since
addition is excessive when the tip end of the float
comes into contact with the stopper.
Float
As a battery electrolyte level warning is provided in the

multifunction display DX, the electrolyte level can generally
be checked at a glance, but open the cap regularly to check
the level.
If the electrolyte level warning indicator LED in the
multifunction display DX shows the following, replenish the
The electrolyte level warning indicator LED blinks • The electrolyte level warning indicator LED lights when the key
when the key is switched OFF. is switched ON.
G428ZZ136_
• The electrolyte level warning indicator LED blinks (LCD back
light blinks) when the key is switched OFF.
If the Battery Protector is Used

The battery protector monitors the level and temperature of
the battery electrolyte and displays warnings on the
multifunction display DX. If a warning is generated, some
vehicle performance is restricted.
Vehicle performance restriction indicator for

battery electrolyte level monitoring.
(accumulated time shown below)
Electrolyte level warning indicator LED (red) remains lit.
G428ZZ137_
Battery electrolyte temperature warning Note:

Never change the installation location of the battery
electrolyte level / temperature sensor.
Reference
The consumption of electrolyte can be calculated by the
following equation:
Consumption (cc) = 5-hour capacity × 0.0336 × Number of
Battery overheat warning indicator LED (red) lights.
cells × Number of times charged
G428ZZ138_
Battery capacity
Number of cells
(AH / 5HR)
7FBR10•13 24 201
7FBR15•18 K 280
1-8
2. Electrolyte inspection
Battery electrolyte is normal when it is transparent.
Check turbidity when inspecting the specific gravity. If
it cannot be checked clearly, put the electrolyte in a
beaker for inspection.
3. Specific gravity inspection

Use a hydrometer and measure the specific gravity of
the electrolyte.
Specific gravity upon full charge:
1.280 [20 °C (68 °F)]
Specific gravity upon end of discharge:
1.150 [20 °C (68 °F)]
The specific gravity of the electrolyte at 20 °C (68 °F)
is used as the standard.
Equation for conversion

S20 = St + 0.0007 (t-20)
S20 = Specific gravity at 20 °C (68 °F)
St: Specific gravity measured at t °C
t: Electrolyte temperature upon measurement (°C)
* How to use the hydrometer

(1) Insert the nozzle of the hydrometer into the
Hydrometer
electrolyte port and allow the electrolyte to
be sucked into its outer tube.
Rubber (2) Let the hydrometer float correctly without
bulb contact with the outer tube, top or bottom,
Outer tube and read the scale at the highest point of
the electrolyte surface as illustrated at left
when the bubbles in the electrolyte
Nozzle
disappear.
(3) After the measurement, wash the inside and
outside of the hydrometer well with clear
water and store it after wiping water off with
clean cloth.
1-9
4. Insulation resistance inspection

Use an insulation resistance meter (megohmmeter)
and measure the resistance between the battery and
battery case.
Insulation resistance: 1 MΩ or more
Note:
• When the insulation resistance is less than 1 MΩ,
wash the battery with water after removing it from
the vehicle.
• Fully dry the washed battery and measure the
insulation resistance again. Install the battery on the
vehicle after confirming that the insulation
resistance is 1 MΩ or more.
* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.
02E_charger.book 1 ページ２０１２年７月９日月曜日午前１１時０分
2-1
CHARGER
Page
GENERAL ...............................................................2-2 NMF
SPECIFICATIONS ...................................................2-2 0
APPLICABLE CHARGER LIST ..................................2-2 1
COMPONENTS .......................................................2-4
2
CHARGER PANEL ASSY ..........................................2-4
3
SPECIFICATIONS ...................................................2-5
BEFORE CHARGING .............................................2-7
4
CHARGER PANEL ASSY .......................................2-8 5
TRANSFORMER ASSY ..........................................2-12 7
INSPECTION AFTER INSTALLATION ........................2-20 9
TIMER TEST ...........................................................2-21 10
11
12
13
14
15
16
17
18
19
20
21
2-2
GENERAL
A fully automatic microcomputer-controlled on-vehicle charger (OPT) and a fully automatic microcomputer-
controlled off-vehicle charger (OPT) are provided.
The on-vehicle charger is not provided on cold storage models.
This manual explains mainly the on-vehicle charger.
Transformer ASSY
Charger panel
G42802DA027_
SPECIFICATIONS
APPLICABLE CHARGER LIST
{ : OPT
Applicable vehicle
Transformer Applicable Power supply 7 7 7 7

Transformer Power supply Battery F F F F
capacity capacity capacity
model voltage voltage B B B B
(50 / 60 Hz) (AH / 5H) (50 / 60 Hz)
R R R R
10 13 15 18
TR4225E 200 V 2.7 / 2.7 48 V 165 to 220 10 / 10 A { {

TR4312E K 3.6 / 3.6 K 240 to 312 15 / 15 A { { { {
TR4370E K 4.5 / 4.5 K 370 15 / 15 A { {
2-3
Correct battery voltage / capacity 48 V, 165 to 220 Ah

Transformer model
Item
TR4225E
Type FW-0
Magnet switch
(MSch)
Rating 12 A
NMF
Thermal setting 11 A
Capacity 50 / 60 Hz 2.7 / 2.7 kVA 0
Transformer
Insulation Type H
(TF)
Weight Approx. 19 kg (41.9 lb)
1
Diode (Dch) Type PT76S8A
2
Fuse (Fch) Capacity 40 A 250 V
3
Correct battery voltage / capacity 48 V, 240 to 312 Ah
Transformer model 4
Item
TR4312E
Type FW-0S
5
Magnet switch
(MSch)
Rating 15 A 6
Capacity 50 / 60 Hz 3.6 / 3.6 kVA 7
Transformer
Insulation Type H
(TF)
8
Diode (Dch) Type PT100S8 9
10
Correct battery voltage / capacity 48 V, 370 Ah
Transformer model
11
Item
TR4370E
12
Type FW-1S
Magnet switch
(MSch)
Rating 26 A 13
Capacity 50 / 60 Hz 4.5 / 4.5 kVA
14
Transformer
(TF)
Insulation Type H
15
Diode (Dch) Type PE608N (+ side), PF608N (– side) 16
17
18
19
20
21
2-4
COMPONENTS
CHARGER PANEL ASSY
4 3
8 9 11 10
G42802DB002_
No. Parts name No. Parts name

1 AC power plug 7 Plug harness No.1
2 Operation panel 8 Magnet harness
3 Magnet switch 9 Wire No.3
4 AC power plug 10 Operation panel
5 Plug harness No.2 11 Magnet wire
6 Plug harness No.3
2-5
SPECIFICATIONS
Circuit Diagram
CIRCUIT DIAGRAM
NMF
PLGAC
MSCH
(B) T W
THR
6 (B)
Z1
TF
FCH 0
T (B) BATT
S
R
(R)
(W)
(R) S V 4 (R)
1
(W) R U 2 (W)
(G)
A1
(W)
A2 96 95 ( L ) 2
(R)
(W)
BOXCH
(L)
DCH
3
M2
Main
4
Display
controller
( ) Shows wire color.

5
6
1 2 6 5 4 3 2 1 7
12 11 10 9 8 7
3 4
8
Z1 M2 G42802ZZ010_
9
No. Potential
Connecting Wire
No. Potential
Connecting Wire 10
to color to color
1 U TRANS W 1 132 CHGMS G-W 11
2 V TRANS R 2 129 CHGAC G-R
3 3 130 CHGGND BR 12
4 W TRANS B 4 128 CHG7V R
5 121 SW3 G
13
6 122 SW2 Y
14
7 123 SW1 O
8 124 LED4 Y-W 15
9 125 LED3 Y-G
10 126 LED2 Y-B 16
11 127 LED1 Y-R
12 17
18
19
20
21
2-6
Charger Panel Wiring
M2
Z1
AC power plug
Magnet wire
Plug harness No.2 Magnet switch
Plug harness No.3 Charger panel bracket
Plug harness No.1
Magnet
harness
Operation
panel
Wire No.3 Name plate
Torque of screw, bolt and nut is according to the table.

Nominal designation Torque T = N·m (kgf·cm) [ft·lbf]
M3.5 0.6 to 0.8 (6.1 to 8.2) [0.44 to 0.59]
M4 1.3 to 1.7 (13.3 to 17.3) [0.96 to 1.25]
Magnet switch
AC power plug
Branch from the

operation panel
Operation panel
Magnet harness
G42802ZZ003_
G42802ZZ012_
2-7
BEFORE CHARGING
If the ampere capacity at the charging location is insufficient because other electrical appliances are being
used, ask an electrical work contractor to provide an exclusive circuit for the charger.
Refer to “APPLICABLE CHARGER LIST” (P2-2) for the AC power supply capacity.
Tap Changer
1. Measure the power supply voltage to be used for
charging.
Tester range: AC (250 or 1000 V)
Note:
Measure the power supply voltage at night (or, if that is
impossible, during a time when electrical appliances
are not being operated).
2. Set the tap changer.

(1) Disconnect the battery plug.
(2) Remove the tap cover of each phase
corresponding to the power supply voltage
measured in step 1 above.
(3) Change the taps.
(4) Connect the charger to the power supply outlet
and press the NORMAL switch.
(5) Measure the voltage between the set taps.
Tap Measured voltage
200 V 191 to 200 V
210 V 201 to 210 V
G42802DC005_ 220 V 211 to 220 V
Note:
• Taps are set to 220 V at the time of shipment.
• Be sure to set the tap changer for phases U, V and W.
• For about a week after tap changer setting, keep track of the battery charging state (specific gravity and
electrolyte level) to make sure the tap setting is appropriate.
Tap layout
50Hz / 60Hz
220V
210V / 220V
U
200V / 210V
200V
220V
210V / 220V
V
200V / 210V
200V
220V
210V / 220V
W
200V / 210V
200V
2-8
CHARGER PANEL ASSY

c
Range of mast movement:

Reach cylinder stroke = 585 mm (23.0 in)
G42802DA003_
Removal Procedure
1 Extend the mast fully forward.
2 Remove the key and disconnect the battery plug.
3 Remove the tray and steering wheel cover, steering
Steering wheel knob wheel knob.
Tray
Steering wheel cover G42802DA004_

2-9
9-5
4 Remove the steering wheel plate.
Steering Note:
wheel plate Refer to page 9-5 for information on attaching the
steering wheel plate.
G42802DA005_
5 Remove the front panel.
Front panel
G42802DA006_
6 Remove the knobs and boots from the material

Knobs
handling levers.
7 Remove the emergency stop lever.
Material handling 8 Open the left door.
lever
Emergency stop lever

Boots
G42802DA007_
2-10
9 Remove the instrument panel.
G42802DA028_
Caution:
Bolt • A number of switches are mounted on the
instrument panel.
To remove the instrument panel, remove the bolts
and raise the instrument panel by approximately
150 mm (5.9 in), then disconnect the switch
connectors.
G42802DA009_
• Remove the boots together with the knobs.

• Remove the emergency stop lever using the same
procedure as for the material handling lever knob.
Bolt
Bolt
G42802DA029_
2-11
10 Disconnect the connector (Z1).
Z1 Connector
G42802DA011_
11 Remove the bolts and take off the charger panel.
Charger panel
Bolt
G42802DA030_
The installation procedure is the reverse of the removal
procedure.
2-12
TRANSFORMER ASSY
Removal Procedure
1 Remove the charger panel.
Note:
Refer to page 2-8 for the removal procedure.
Charge panel
Bolt
G42802DA030_
2 Remove the center panel.

Caution:
Connectors for a number of switches are mounted on
the center panel. Disconnect these connectors.
Center
panel
Bolt
G42802DC002_
3 Disconnect the harness and cable from the pump

Pump motor motor.
Harness
Cable G42802DA014_
4 Put ropes around the pump motor.

Caution:
• Loop 2 ropes under the pump motor.
Use rags or other padding to prevent damage to
plastic parts and sensors.
• Use a hoist to adjust the tension so that there is no
play in the ropes.
G42802DA015_
2-13
5 Remove the nut of left side motor bracket.

Nut
G42802DA016_
6 Remove the oil pump mounting bolt.

Pump motor
Oil pump
Bolt
G42802DA018_
7 Disconnect the right side motor bracket and pump

motor.
Right side
motor bracket
Bolt
G42802DA019_
2-14
8 Move the pump motor approximately 33 mm (1.3 in.)

to the left and then winch it upwards to remove it.
Caution:
Raise the motor slowly to avoid snagging any of the
wiring.
G42802DA020_
G42802DC003_
9 Disconnect input cable and the 2 cables running out of

the transformer ASSY from the clamps.
Input cable
Cable
G42802DA021_
2-15
10 Remove the contactor cover attached to the upper

cover.
Upper cover
Bolt
G42802TA001_
11 Disconnect the charger cables (P2 and N).

Charger cable (P2)
Pump AC driver
Contactor panel
Charger cable (N) G42802DC004_
aa
12 Attach the winching shackle and wire to the

transformer ASSY and connect the wire to the hoist.
Wire
Schackle
Transformer ASSY
G42802DA023_
2-16
Left side of vehicle 13 Remove the transformer ASSY mounting bolt.

(2 places)
Bolt
G42802DA024_
Front side of vehicle
Bolt
G42802DA025_
14 Remove the transformer ASSY from the vehicle.
G42802DA026_
procedure.
2-17
Inspection Magnet Switch

Inspect the magnet switch contact continuity.
Press MSch: ON Tester range Ω×1
Measurement terminals T - W, S - V and R - U
MSch ON 0Ω
Standard
MSch OFF ∞Ω
Inspect the magnet switch coil continuity.

Tester range Ω×1
Measurement terminals A1 - A2
FW-0S 1150 ± 10 Ω
Standard FW-0 1150 ± 10 Ω
FW-1S 460 ± 10 Ω
Inspect the thermal relay contact continuity.

Tester range Ω×1
Measurement terminals 95 - 96
Not operating 0Ω
Standard
Operating ∞Ω
Inspect the reset switch.

Check that the thermal relay is deactivated upon pressing
FW-0S•FW-0 FW-1S
the reset switch while the thermal relay is activated.
Test switch
Do not adjust the thermal relay operating current.
If charging stops due to thermal relay activation while the
charger is in use, always check the thermal relay activating
cause and reset after taking corrective action.
Press the reset switch lightly to reset the thermal relay.
Reset switch Reset switch

2-18
To test the thermal relay, set the activation state as follows.

FW-0S
Pull the reset switch.
FW-0
Use a thin screwdriver to move the reset
FW-1S
switch to the left.
96 95 96 95
Not operating Operating
Inspection Transformer ASSY

Inspect the fuse.
Standard: 0 Ω
Measure the insulation resistance.

Measuring instrument 500 VDC megohmmeter
Measurement terminals Each coil terminal - Frame
Standard 1 MΩ or more
G42802DC006_
Measure the primary coil continuity.

Tester range Ω×1
Measurement terminals U1 - V1, V1 - W1 and W1 - U1
Standard 0Ω
G42802DC007_
2-19
TR4225E•TR4312E Measure the secondary coil continuity.

Tester range Ω×1
U2
Measurement terminals U2 - V2, V2 - W2 and W2 - U2
V2
Standard 0Ω
W2
TR4370E
W2 V2 U2
U2 V2 W2
G42802TA002_
TR4225E•TR4312E Measure the diode continuity.

Inspect the diodes installed on the radiating fin plate and
remove only if an abnormality is found.
Tester range Ω × 1k
Measurement Forward Anode (–) - Cathode (+)
terminals Reverse Anode (+) - Cathode (–)
Forward Continuity
U2 Standard
V2 Reverse ∞Ω
W2
Note:
• As two diodes with different polarity are used, be
sure to avoid incorrect installation.
TR4370E • Install each diode by tightening to the specified
torque.
U2 V2 W2 T = 2.6 ± 0.2 N·m (26.5 ± 2 kgf·cm) [58.4 ± 0.15 ft·lbf]
W2 V2 U2
G42802TA003_
2-20
INSPECTION AFTER INSTALLATION

1. Inspect each wiring connection.
Note:
Check each wiring connection by referring to the
charger wiring diagram.
2. Measure the insulation resistance.

Measuring instrument 500 V DC megohmeter
Measurement terminals Each coil terminal - Frame
Standard 1 M Ω or more
G42802DC008_
3. Measure the no-load secondary voltages.

With the battery plug disconnected, connect the
charger plug to the power supply, start charging (by
pressing the NORMAL switch) and measure the
following items:
Tester range 250 V DC
Controller side battery
Measurement Between both terminals
terminals (+) terminal : (-) probe
(+) terminal : (-) probe
TR4225E : 74 / 78 V
Standard
TR4312E : 76 / 80 V
50 / 60 Hz
TR4370E : 71 / 74.5 V
2-21
TIMER TEST
Multifunction display DX initial screen
Operating Procedure
1. Connect the battery plug to the AC power plug.
2. Two seconds after the battery plug is connected, the
multifunction display DX screen shows the initial timer
test screen.
G42802TA007_
Charger operation panel 3. Hold down the START switch (4) and STOP switch (5)
at the same time on the charger panel until you hear a
(3) (1) (2)
short double beep. At this point, all the LEDs light and
the timer is in timer test standby mode.
4. Within 5 seconds of initiating timer test standby mode,
press the START switch (4) to start the timer test. At
this point, the "NOW TESTING!" message appears on
the multifunction display DX screen.
(If the LEDs turn off before you can start testing,
repeat step 3.)
(5) (4)
G42802ZZ013_
(1) EQUAL LED (Yellow)

(2) NORMAL LED (Yellow)
(3) UP LED (Green)
(4) START switch
(5) STOP switch
Test items
• At the same time as the "NOW TESTING!" message
appears, the magnet switch also engages.
• The capacity meter bar on the multifunction display
DX extends by one bar each second after the timer
test starts.
• The LEDs on the charger panel light in sequence as
follows: (1) J (2) J (3).
G42802TA005_
2-22
• 10 seconds after testing starts

The capacity meter bar shows 10 bars.
The UP LED lights.
The magnet switch disengages.
At the same time, the multifunction display DX
displays the "NOW COMPLETED" message.
5. After confirming that the "NOW COMPLETED"
message is displayed, press the STOP switch. The
initial timer test screen reappears on the multifunction
display DX screen and the UP LED turns off.
Caution:
• If the LEDs do not light when you connect the AC
G42802TA006_
power plug, press the STOP switch and then
disconnect the AC power plug. Then check that the
AC power plug is connected to an AC 200 V power
supply.
• If there is no problem with the AC 200 V power
supply, connect the AC power plug again and carry
out the test from the beginning.
• If the LEDs still fail to light when the test is
repeated, the unit has failed the test.
06E_motor.book 1 ページ２０１２年７月６日金曜日午後４時８分
6-1
MOTOR
Page
DRIVE MOTOR........................................................6-2 NMF
GENERAL ...............................................................6-2 0
SPECIFICATIONS ....................................................6-4 1
COMPONENTS ........................................................6-5
2
REMOVAL•INSTALLATION .......................................6-6
3
PUMP MOTOR ........................................................6-9
GENERAL ...............................................................6-9
4
SPECIFICATIONS ....................................................6-11 5
COMPONENTS ........................................................6-12 6
POWER STEERING MOTOR..................................6-14 8
GENERAL ...............................................................6-14
9
SPECIFICATIONS ....................................................6-14
10
COMPONENTS ........................................................6-15
11
DISASSEMBLY•INSPECTION•REASSEMBLY .............6-17
12
13
14
15
16
17
18
19
20
21
6-2
DRIVE MOTOR
GENERAL
Terminal cover
When installing the radial ball bearing,
Die-cast rotor
apply NPC grease spray to the outside of
the bearing.
Hole snap ring
End bracket
Stator W/coil the bearing.
Terminal
Hexagon nut
T = 50.0 to100.0 N·m
(509.9 to 1019.7 kg·cm)
[36.89 to 73.78 ft·lbf]
Locking agent applied
Name plate W V U
C
Collar
Pickup gear
Stud bolt
Flange nut
17 mm (0.67 in)
T = 14.4 to 21.6 N·m C
Tighten the bolt in until the end of the (146.8 to 220.3 kgf·cm)
bolt reaches the incompletely [10.62 to 15.93 ft·lbf]
threaded section.
Plate washer Nut W/washer
A-A Section view
End bracket T = 11.0 to 15.0 N·m
(112.2 to 153.0 kgf·cm)
[8.1 to 11.1 ft·lbf]
Wiring harness clamp

Temperature sensor
(Drive motor) (STDM) Cover plate
Flange bolt
A
Speed sensor 2
B
(Drive motor) (SSD2)
Temperature sensor
bracket
Ø140 mm (5.51 in)
Nut
A
65.2 mm (2.57 in)
5 mm (0.2 in) Speed sensor 1
B (Drive motor) (SSD1)
40 mm (1.57 in) G42806TA001_
6-3
Lead wire
Terminal
Cover plate Lead wire
End bracket
NMF
Terminal 0
End bracket
Coil exterior 1
Essentials of terminal and cover plate installation 1 Essentials of terminal installation 2
Ensure that there is no interference between the lead wire, the Ensure that there is no interference between the lead wire 2
coil exterior and terminal and the cover plate. and the terminal.
Leave clearance of at least 3.5 mm (0.14 in) between the lead
wire and the coil exterior and terminal.
Leave clearance of at least 3.5 mm (0.14 in) between the
lead wire and the coil exterior and end bracket.
3
4
Essentials of speed sensor (drive motor) installation 5
Bolt W/washer
Bolt W/washer
6
Nut
7
8
Speed sensor (Drive motor)
9
C-C Section view
10
B-B Section view
Clearance 11
0.79 ± 0.53 mm
(0.31 ± 0.02 in)
12
13
Locking agent application Drive motor shaft 14
15
2m Hexagon nut
16
m
(0.0
or m
78 i
ore )
n
Pickup gear
17
Seal lock
Three Bond 1401B
18
19
20
G42806TA002_
21
6-4
SPECIFICATIONS
Item Specification
Type Type 3-phase AC, open type
Nominal voltage 48 V
Rated output 4.9 kW
Rated voltage 30 V
Constitution
Ø 192 × 246
(Outside diameter × length)
Weight 26 kg (57.3 lb)
Insulation class Class F
6-5
COMPONENTS
27
9 14 NMF
0
2
13 14
21 8 11 1
20
22 6
23 2
24 14
3
3
28 1812 25
7 15 4
5
17
16
6
1 19
14
7
4
26 5 10
8
G42806DA007_ 9
1 Plate, cover 15 Nut 10
2 Cover, terminal 16 Nut, flange
3 Plate, name 17 Washer, plate
11
4 Speed sensor (Drive motor) 18 Ring, hole snap
12
5 Gear, pickup 19 Bolt, flange
6 Bracket, temperature sensor 20 Temperature sensor (Drive motor) 13
7 Collar 21 Shaft, drive motor
8 Clamp, wiring harness 22 Rotor, die-cast 14
9 Bolt, stud 23 Nut, flange
10 Nut, hexagon 24 Bolt, flange 15
11
12
Nut, W/ washer
Bearing, radial ball
25
26
Terminal
Bracket end
16
13 Bearing, radial ball 27 Bracket end 17
14 Bolt, W/washer 28 Stator W/coil
18
19
20
21
6-6
Removal Procedure
1 Remove the pump motor and transformer ASSY.
(See page 2-12.)
2 Disconnect the harness and cable from the drive
motor and brake limit switch.
Note:
After removing the bracket, temporarily secure the
cover plate.
3 Remove the terminal guide plate
4 Remove the brake limit switch. (See page 11-12.)
Brake limit switch
G42806DB001_
Cover plate
Bracket
View A
View B
T = 3 to 7 N·m (30.6 to 71.4 kgf·cm)

[2.2 to 5.2 ft·lbf]
Terminal guide plate
G42806DB002_
6-7
5 Disconnect the brake wire.

(See page 11-6.)
Brake wire
G42806DB003_
6 Attach a wire rope to the drive motor.

Caution:
Use rags or other padding to prevent damage to
functional parts.
G42806DB007_
7 Remove the drive motor mounting bolt.

T = 50 to 114 N·m (510 to 1163 kgf·cm)
[50 to 80 ft·lbf]
Bolt
G42806DB004_
Bolt
G42806DB005_
6-8
(1)
(2)
G42806DB006_
8 Remove the drive motor W/disc brake ASSY from the

vehicle.
Note:
Take the drive motor out while rotating it
anticlockwise.
Caution:
Be careful to avoid damage to adjacent functional
parts.
procedure.
6-9
PUMP MOTOR
GENERAL
When installing the radial ball bearing, Terminal cover
apply NPC grease spray to the outside of Hole snap ring
the bearing.
Stator W/coil
the bearing.
Die-cast rotor Pickup gear

Terminal Name plate
Plate washer
Washer
base head C
hexagon bolt
T = 13.0 N·m
(132.6 kgf·cm)
[9.59 ft·lbf]
Flange nut
T = 18.0 N·m
17 mm (0.67 in) (183.5 kgf·cm)
[13.27 ft·lbf] C
Tighten the bolt in until the end of Nut W/washer
Plate washer T = 11.0 to 15.0 N·m
the bolt reaches the incompletely
threaded section. Stud bolt (112.2 to 153.0 kgf·cm)
End bracket End bracket [8.1 to 11.1 ft·lbf]
Temperature sensor bracket
A-A Section view Temperature sensor
A
(Pump motor) (STPM)
Wiring
harness clamp
Flange bolt
T = 5.0 N·m
B (51.0 kgf·cm)
[0.182 ft·lbf]
Cover plate
Speed sensor
(Pump motor)
(SSP)
A
B Nut
Flange bolt
T = 5.0 N·m
(51.0 kgf·cm) Sensor cover
[0.182 ft·lbf] G42806TA003_
6-10
Lead wire
Terminal Lead wire
Cover plate
End bracket
Terminal
End bracket
Coil exterior
Essentials of terminal and cover plate installation 1 Essentials of terminal installation 2

Ensure that there is no interference between the lead wire, the Ensure that there is no interference between the lead wire
coil exterior and terminal and the cover plate. and the terminal.
Leave clearance of at least 3.5 mm (0.14 in) between the lead Leave clearance of at least 3.5 mm (0.14 in) between the
wire and the coil exterior and terminal. lead wire and the coil exterior and end bracket.
Essentials of speed sensor (pump motor) installation

Speed sensor Bolt W/washer
(Pump motor)
Bolt W/washer
Nut
B-B Section view C-C Section view
Clearance
0.79 ± 0.53 mm
(0.31 ± 0.02 in)
G42806TA004_
6-11
SPECIFICATIONS
Item Specification
Type Type 3-phase AC, open type
Nominal voltage 48 V
Rated output (5 min rating) 8 kW
Rated voltage 23 V
Constitution
Ø 192 × 256
(Outside diameter × length)
Weight 25 kg (55.1 lb)
6-12
COMPONENTS
16
30 7
10
13 16 11
23 22 27
8 16
28
5
25 24
1 29
21 20
14
17
3 19
18
9 4
2
16 6 15
15
12
26
G42806DA008_

1 Plate, name 16 Bolt, W/washer
2 Speed sensor (Pump motor) 17 Nut
3 Gear, pickup 18 Nut, flange
4 Cover, sensor 19 Washer, plate
5 Temperature sensor bracket 20 Ring, hole snap
6 Plate, cover 21 Stator, W/coil
7 Cover, terminal 22 Temperature sensor (Pump motor)
8 Clamp, wiring harness 23 Rotor, die-cast
9 Bolt, washer based head hexagon 24 Shaft, No.1
10 Bolt, stud 25 Shaft, No.2
11 Nut, W/washer 26 Bracket, end
12 Washer, plate 27 Nut, flange
13 Bearing, radial ball 28 Bolt, flange
14 Bearing, radial ball 29 Terminal
15 Bolt, flange 30 Bracket, end
6-13
Removal Procedure
1 Remove the pump motor. (See page 2-12.)
6-14
POWER STEERING MOTOR

GENERAL
SPECIFICATIONS
Type DC permanent magnet
Nominal voltage V 48
Rated output kW 0.26
Constitution
Ø 86 × 154 (3.39 × 6.06)
(Outside diameter × length) mm (in)
Weight kg (lb) 2.9 (6.39)
Brush size
6 × 15 × 20 (0.24 × 0.59 × 0.79)
(thickness × width × length) mm (in)
Number of brushes 2
6-15
COMPONENTS
G42806ZZ005_

01 PS Motor ASSY 40 Brush
01A Bearing 45 Spring, PS motor brush
01B Bearing AA Bolt
10 Yoke AC Bolt
11 Brush holder AD Washer, spring
12 PS Armature ASSY AY Bolt
15 Frame ASSY, commutator
6-16
T = N·m (kgf·cm) [ft·lbf]
Screw tightening torque

T = 6.9 to 16.1
(70 to 165)
[5.1 to 11.9]
G42806DB008_
Removal Procedure
2 Disconnect the connector.
3 Remove the PS motor set bolts.
4 Remove the PS motor ASSY.

6-17
1 Remove the yoke.
2 Free the brush.
3 Remove the armature coil from the bracket. [Point 1]
4 Remove the brush from the brush holder. [Point 2]
5 Remove the brush holder and armature bearing lock plate from the bracket. [Point 3]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Check the insulation between the motor connector terminal and the motor body after reassembly.
Standard: 1 M Ω or more (with a DC 500 V megohmmeter)
6-18
Point Operations
[Point 1]
SST
Inspection:
Inspect the bearing and replace it if abnormal.
(1) Remove the armature bearing on the
bracket side.
SST 09950-76014-71 (09950-40011)
(2) Install the bearing.

SST 09700-30200-71
SST
Inspection:
If the commutator surface is roughened, correct it with
sandpaper (#600 or similar) and clean it well.
If the surface is excessively rough, repair with a lathe.
Standard: 33 mm (1.30 in)
Limit: 31.5 mm (1.24 in)
Inspection:
When the commutator is repaired, undercut the mica.
Amount of undercutting
Undercut Standard: 0.8 mm (0.031 in)
Limit: 0.3 mm (0.012 in)
Mica
Inspection:
Measure the commutator runout.
Standard: 0.05 mm (0.00197 in) or less
6-19
Inspection:
Measure the insulation resistance of the armature coil.
Standard: 1 M Ω or more
[Point 2]
Inspection:
Check the brush for wear and contact state.
Brush length
Limit: 11 mm (0.43 in)
Inspection:
Reassemble the armature coil and brush, hook a spring
scale to the brush spring, and measure the spring force
the instant the spring leaves the brush.
Spring force
Standard: 1.76 to 5.59 N (0.18 to 0.57 kgf)
[3.88 to 1.26 lbf]
[Point 3]
Inspection:
Measure the insulation resistance between the brush
holder and the bracket.
Standard: 1 M Ω or more
Inspection:
Inspect the bearing and replace it if abnormal.
07E_driveunit.book 1 ページ２０１２年７月６日金曜日午後４時１０分
7-1
DRIVE UNIT
Page
GENERAL ...............................................................7-2 NMF
SPECIFICATIONS ...................................................7-3 0
COMPONENTS .......................................................7-4 1
DRIVE UNIT ............................................................7-6
2
3
DISASSEMBLY•REASSEMBLY .................................7-9
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
7-2
GENERAL
Lock nut:
Coupling drive amount

Measure the starting force.
Apply Molywhite TA No. 1 on the
Coupling: spline portion.
4 mm (0.157 in):
Check the identification mark.
Lock bolt
Gear case cover: A

Lock nut
Apply three bond liquid gasket
O-ring plate
1271C (black) to the matching Case cover bearing:
surfaces. Add grease (see table below).
Lock nut:
T = 50 to 90 N·m Bearing
Bolt: T = 34 to 50 N·m
(510 to 918 kgf·cm) (347 to 510 kgf·cm)
[36.9 to 66.4 ft·lbf] [25.1 to 36.9 ft·lbf]
Do not omit the caulking. C
B
B Turn gear:
Apply Molycote 321.
Driven gear
Retainer
Oil level Bearing
Bearing
Shim: 0.10 mm (0.0039 in) Bearing
0.15 mm (0.0059 in) 3.5 mm Drive gear
0.20 mm (0.0079 in) Bearing (0.138 in) Idler gear
0.25 mm (0.0098 in)
Bearing spacer
Gear case
Tire outside diameter:

Bearing
Bolt: T = 20 to 30 N·m
334 mm (13.1 in)

(204 to 306 kgf·cm)
[14.8 to 22.1 ft·lbf]
Gear case side cover:
F mark to be on the outside. Bolt:
Apply three bond liquid T = 118 to 166 N·m
gasket 1271C (black). (1203 to 1693 kgf·cm)
[87 to 122 ft·lbf]
Oil seal
R15 available radius with no load:
Gear set
Bearing Drive wheel shaft
Lock nut: T = 312 to 468 N·m Bearing
(3180 to 4770 kgf·cm)
[230 to 345 ft·lbf]
158 mm (6.2 in)
Do not omit the caulking.

Spacer
Gasket
Drain plug
T = 20 to 30 N·m
(204 to 306 kgf·cm)
[14.8 to 22.1 ft·lbf] Shim: 0.20 mm (0.0079 in) Add grease to C section
0.25 mm (0.0098 in) (see table below).
0.30 mm (0.0118 in)
0.60 mm (0.0236 in)
G42807ZZ002_
Specifications Gear oil Grease (Turn bearing section)

Standard TOYOTA hypoid gear oil SX85W-90 Auto rex A grease
Cold storage models Castle hypoid gear oil W Esso beacon 325
7-3
0.4 ± 0.4 mm (0.0157 ± 0.0157 in) (Drive amount)
Apply hermeseal 101Y around the outside of

the oil seal and to the oil seal mounting area
on the gear case. NMF
0
B-B Section view 1
2
C
3
View A
C
4
Shim: 0.10 mm (0.0039 in)
0.15 mm (0.0059 in) 5
0.25 mm (0.0098 in) Straight pin (2 psc)
0.60 mm (0.0236 in)
Select shims such that the backlash
Bolt: 6
T = 76 to114 N·m
in the ring gear and drive pinion is
0.13 to 0.18 mm (0.005 to 0.007 in).
(775 to 1162 kgf·cm)
[56.1 to 84.1 ft·lbf]
7
Bolt (8 psc):
T = 76 to114 N·m
Breather plug
Gasket
8
(775 to 1162 kgf·cm) Washer
[56.1 to 84.1 ft·lbf]
Plug: T = 64 to 96 N·m
C-C Section view 9
(650 to 970 kgf·cm) [47.2 to 70.8 ft·lbf]
Confirm that there is a groove.
Oil level
Bottom edge of the plug socket hole
10
Adding gear oil 11
• Add approx. 1.85 l (0.5 US gal.) of gear oil.
• Check the oil level in the plug socket hole.
If the level is low, add oil to the stipulated amount.
12
Coupling identification mark
G42807ZZ003_ 13
SPECIFICATIONS 14
15
Items
Reduction gear type Spiral bevel gear 16
Drive 19
Helical gear single
Driven 80 17
Number of gear Drive 18
teeth
Helical gear double
Driven 25 18
Drive 9
Spiral bevel gear
Driven 37
19
Total reduction ratio 24.042 20
Drive unit gear oil amount l (US gal) Approx. 1.85 (0.5)
21
7-4
COMPONENTS
AA
AB
AC
40B
AF
40C
42 AU
AG
AZ
40
AT AH
AD
41 AK
AI AE
BQ
G42807ZZ004_

40 Gear case cover AF Bolt
40B Case cover bearing No.1 AG Washer
40C Case cover bearing No.2 AH Plug
41 Gear case AI Gasket
42 Turn gear AK Bolt
AA Lock bolt AT Straight pin
AB Lock nut AU Breather plug
AC Lock nut plate AZ Bolt
AD Gasket BQ Gear case side cover
AE Drain plug
7-5
73
72
87 NMF
85
82
52
0
76
65
71 84
81
1
83
66
80
79 2
78
68 3
77
64
69 86
4
67 5
70
6
75
7
89 8
9
74
10
90 88 91 92 94 93 96 95 97 98
11
G42807DB001_
No. Parts name No. Parts name 12

52 Bolt W/washer 81 Shim
64 Drive gear 82 Shim 13
65 Coupling 83 Shim
66 O-ring 84 Shim
14
67 Bearing 85 Shim
15
68 Bearing 86 Bearing
69 Idler gear 87 Bearing 16
70 Bearing 88 Drive wheel shaft
71 Bearing 89 Lock nut 17
72 Driven gear 90 Bolt
73 Lock nut 91 Oil seal
18
74 Ring gear 92 Bearing
19
75 Drive pinion 93 Bearing
76 Retainer 94 Spacer 20
77 Bearing spacer 95 Shim
78 Shim 96 Shim 21
79 Shim 97 Shim
80 Shim 98 Shim
7-6
DRIVE UNIT
Removal Procedure
1 Jack up the vehicle and support it with wooden block.
If the vehicle height is less than the standard, the drive
unit may not be drawn out.
Approx. 40 cm (15.75 in)

(Reference value)
2 Remove the pump motor and drive motor.

(See page 6-6.)
G42807DA001_
3 Drain the oil from the drive unit using the procedure
Fill opening below.
(1) Rotate the steering wheel approximately 60° to
bring the drain plug to the front.
(2) Remove the drain plug and drain the oil.
(3) After all the oil has drained out, re-insert the drain
plug.
Drain plug
G42807DA002_
7-7
Note:
• If the oil drains poorly, remove the plug from the fill
Fill opening
opening.
• After you install the drive unit, add oil through the
fill opening.
(Refer to page 7-2 for information on the fill amount
and adjustment method.)
G42807DA006_
4 Remove the lock nut.

Lock bolt
Lock nut
Lock nut plate
G42807DA003_
5 Put ropes around the turn gear.

6 Tap the gear case cover with a plastic or copper mallet
and remove the drive unit.
G42807DA004_
G42807ZZ005_
7-8
7 When lowering, pull toward the front while rotating the

drive wheel.
G42807ZZ001_
Note:
With the drive unit removed
G42807DA005_
procedure.
7-9
DISASSEMBLY•REASSEMBLY
1 Remove the drive wheel.
Drive wheel
G42807DB002_
2 Remove the gear case side cover.
Gear case side cover

G42807DB003_
Lock nut G42807ZZ006_

7-10
4 Using a plastic or copper mallet, remove the drive

wheel shaft by tapping the end of the shaft from the
gear case side cover side.
G42807ZZ007_
Ring gear Bearing spacer Oil seal
Bearing Drive wheel shaft

Shim
Tapered roller bearing
G42807ZZ008_
5 Remove the turn gear.

Turn gear
G42807DB004_
7-11
6 Remove the gear case cover set bolt.
G42807DB005_
7 Remove the gear case cover and coupling.

Gear case cover
Coupling
G42807DB006_
8 Use a screwdriver to remove the drive gear W/bearing

and idler gear W/bearing at the same time.
Drive pinion 9 Remove the drive pinion W/retainer ASSY set bolt.
W/retainer ASSY
set bolt
G42807DB007_
7-12
Drive pinion
10 Remove the drive pinion W/retainer ASSY.
W/retainer ASSY
G42807DB008_
Note:
Reassembled drive pinion W/retainer ASSY.
Lock nut
Driven gear
Shim
Bearing
Shim
Spacer
Bearing
Drive pinion
G42807ZZ009_
7-13
Adjustment Procedure
Use the procedure below to adjust the starting force for the
drive pinion W/retainer ASSY.
1 Set a spring scale at the retainer flange bolt hole, and
measure the starting force.
Standard: 18 to 22 N (1.84 to 2.24 kgf)
[4.05 to 4.93 lbf]
2 If the starting force does not satisfy the standard,

adjust by means of shims inserted between the
bearing and spacer.
Shim thickness mm (in):
0.10 (0.0039), 0.15 (0.0059), 0.20 (0.0079),
0.25 (0.0098)
3 When the driven gear is installed, always caulk the
Shim lock nut in 2 places after starting force adjustment.
Ring gear
F = 14 to 30 N
(1.4 to 3.1 kgf) Oil seal
[3.1 to 6.7 lbf]
200 mm (7.87 in)

Lock nut
G42807DB009_
Apply lithium spray grease to the oil seal prior to measurement.

Lock nut width across 2 faces: 50 mm (1.97 in)
7-14
Inspect and adjust the backlash between the drive pinion

and ring gear.
1. Rotate the drive wheel shaft and measure the
backlash.
Standard: 0.13 to 0.18 mm (0.005 to 0.007 in)
Note:
Measure the backlash at tooth flanks close to the
center of the ring gear.
2. If the standard is not satisfied, change the shims for

adjusting drive pinion protrusion and measure the
backlash again
Shim thickness mm (in):
0.10 (0.0039), 0.15 (0.0059), 0.25 (0.0098), 0.6 (0.0236)
G42807DB010_
7-15
Checking teeth contact

After cleaning the gear tooth flanks, apply red lead primer thinly and uniformly on 9 to 10 gear tooth flanks and
rotate the drive wheel shaft in the forward and reverse directions to inspect teeth contact.
l1
Small end
b (inside)
n)
t 39i
0
(0.
m m
(0.039 in)
1
1 mm
l2
Lapping line
5 mm
(0.197 in)
n
h
Large end
(outside) 0.5 mm
(0.002 in)
Teeth contact area
(1) Teeth contact must be within the lapping lines.
(2) l1 must be less than l2 (teeth contact at the small end)
(3) t must exceed 1/3b and exceed 9
(4) h must exceed 1/3b and exceed 2.7
All items (1) to (4) must be within the standards.

G42807ZZ011_
7-16
If the teeth contact is not correct, adjust drive pinion

protrusion, ring gear shims, and backlash. After ring gear
shim adjustment, adjust the ring gear bearing starting force
again.
(1) Heel contact

Decrease the drive pinion shim thickness to bring
the drive pinion closer to the ring gear, and then
decrease the ring gear shim to bring the ring gear
away from the drive pinion.
(2) Toe contact

Increase the drive pinion shim thickness to bring
the drive pinion away from the ring gear, and then
increase the ring gear shim to bring the ring gear
closer to the drive pinion.
(3) Flank contact (low, shallow contact)

Increase the drive pinion shim thickness to bring
the drive pinion away from the ring gear, and then
increase the ring gear shim to bring the ring gear
closer to the drive pinion.
7-17
(4) Face contact (high, shallow contact)

Decrease the drive pinion shim thickness to bring
the drive pinion closer to the ring gear, and then
decrease the ring gear shim to bring the ring gear
away from the drive pinion.
Caulking the lock nut

After adjusting the starting force, securely caulk the
Caulk
lock nut to prevent loosening.
Caulk
Drive pinion section

A
Caulk Caulk
No cracking
Gap up to
0.5 mm (0.02 in)
permissible
Firmly bend angles as fulcrums.
View A
Ring gear section
No cracking
Caulk Gap up to
1.0 mm (0.039 in)
permissible
A
Caulk
Firmly bend angles as fulcrums.
View A
G42807ZZ012_
7-18
After the end of assembly, measure the starting force at

the coupling portion using the SST.
SST 09340-13900-71
Standard: 3.0 N (0.31 kgf) [0.7 lbf] or less /
200 mm (7.87 in)
200 mm
(7.87 in)
SST
G42807ZZ013_
Measure the drive unit starting force.

Standard: 30 to 52 N (3.1 to 5.3 kgf)
[6.7 to 11.7 lbf]
F = 30 to 52 N
(3.1 to 5.3 kgf)
Dimension: 142 mm (5.59 in)
[6.7 to 11.7 lbf] Note:
• After completing drive unit reassembly, apply grease to
the bearing and then measure the starting force.
• Always secure the unit with screws after making
adjustments.
142 mm (5.59 in)
G42807ZZ010_
08E_sus.book 1 ページ２０１２年７月６日金曜日午後３時２８分
8-1
SUSPENSION & CASTER WHEEL

Page
GENERAL ...............................................................8-2 NMF
SUSPENSION..........................................................8-2 0
CASTER WHEEL .....................................................8-3 1
SPECIFICATIONS ...................................................8-3 2
COMPONENTS .......................................................8-4
3
CASTER WHEEL .....................................................8-4
4
SUSPENTION ..........................................................8-5
CASTER WHEEL ....................................................8-6
5
CASTER ARM AND CASTER LEG ........................8-8 7
SWING LOCK CYLINDER ......................................8-12 9
10
SUSPENSION SPRING ..........................................8-14
11
12
SUSPENSION SHAFT ............................................8-16
DRIVE UNIT SUPPORT ..........................................8-19 14
METHOD FOR APPLYING 16
GREASE TO SUSUPENSION..................................8-21
17
18
19
20
21
8-2
GENERAL
SUSPENSION
8
Front
Drive motor
Suspension spring
Bracket
EPS gear
Tire angle sensor
Drive unit support

Drive motor
mounting bolt
PS motor
Suspension shaft & coupling
Caster & spring

Drive unit
PS motor
mounting bolt
Grease fitting
Swing lock cylinder Caster leg
Caster tire
Wheel shaft pin Bearing & wheel cover
G42808DA001_
8-3
CASTER WHEEL
NMF
0
1
2
3
4
5
G42808TA001_
6
SPECIFICATIONS
7
Vehicle model
7FBR10·13 7FBR15·18 8
Item
Rear axle suspension type
Trailing arm automatic
I 9
wheel pressure type
Caster type Center pivot type I 10
Tread mm (in) 545 (21.46) 645 (25.39)
Outer : 118 (4.65) 11
Free length mm (in) 118 (4.65)
Inner : 101
Suspension spring
Installed length 12
90 (3.54) I
(adjusted dimension) mm (in)
Caster spring (2 pcs) Free length mm (in) 71.5 (2.81) I 13
14
15
16
17
18
19
20
21
8-4
COMPONENTS
CASTER WHEEL
44
48B
40D
41
40A
AY
AB AC
45
FE
40
46
AA 42A 42
AF 30
G42808TA002_

30 Wheel shaft pin 45 Bearing
40 Caster leg 46 Oil seal
40A Bearing AA Bolt
40B Lock nut AB Washer
40D Plate AC Snap ring
41 Wheel cover AF Grease fitting
42 Wheel shaft AY Wheel bolt
42A Bush FE Snap ring
44 Cap
8-5
SUSPENTION
BZ
BC
AU
AU
CU AZ DF AK
AK BT
NMF
BW BB
40 AR
AH DG
DK CX
DB
0
43
CW DE
20A DA BO
CT
CZ
1
FIG.4502-72
20
AB
2
AB
CV BP 41
AS
DD
CY
AP
BI
DO 3
CT CN
AH
4
BJ DC
DI
AL DJ AA
BO
BO CF BY
AL
AI AI 11
AL
5
CG BI
DH
BO
CS
CH
6
AI DN
CG
BD
G42808ZZ004_

11 Swing lock cylinder BZ Bolt
20 Suspension shaft CF Plate 8
20A Bush CG Hose
40 Suspension spring CH Hose
9
41 Spring CN Spring washer
10
43 Suspension spring CS Band
AA Bolt CT O-ring 11
AB Nut CU Stopper
AH Grease fitting CV Drive unit support 12
AI Connector CW Collar
AK Washer plate CX Coupling
13
AL
AP
Connector
Bolt
CY
CZ
Bush
Bush
14
AR Shim DA Spring arm 15
AS Washer plate DB Shaft
AU Washer spring DC Caster arm 16
AZ Nut DD Pin
BB Bolt DE Bush 17
BC Bolt DF Bush
BD Bolt DG Spring pin
18
BJ Bolt DH Pin 19
BI Bolt DI Pin
BO Grease fitting DJ Sponge 20
BP Stopper DK Adaptor
BT Bracket DN Grease fitting 21
BW Spacer DO Bush
BY Grease fitting
8-6
CASTER WHEEL
T = 68 to 108 (693 to 1,101) [50 to 80]

(Apply loctite 242.)
3
4
7
9
T = 68 to 108 (693 to 1,101) [50 to 80] 8

(Apply loctite 242.)
9 2 2
7 T = 22 to 50 (224 to 510) [16 to 37]
3 4
Removal Procedure
1 Jack up the vehicle and support it with wooden blocks. (See page 0-8.)
2 Remove the caster wheel. [Point 4]
3 Remove the wheel cover.
4 Remove the wheel bolts.
5 Remove the wheel from the wheel shaft.
6 Remove the collar from the wheel shaft. [Point 1]
7 Remove the snap ring.
8 Remove the oil seal. [Point 2]
9 Remove the wheel bearing. [Point 3]
Point Operations
[Point 1]
Installation:
SST(1) Use the SST to install the collar.
SST 09950-76020-71 (09950-70010) ... (1)
SST(2) 09950-76018-71 (09950-60010) ... (2)
8-7
[Point 2]
Removal:
SST Use the SST to remove the oil seal.
SST(1)
SST (2)
SST 09308-76001-71 (09308-00010)
Installation:
Use the SST to install the oil seal.
SST 09950-76020-71 (09950-70010).... (1)
09950-76018-71 (09950-60010).... (2)
[Point 3]
Installation:
SST (2) Use the SST to install the wheel bearing.
A
SST 09950-76020-71 (09950-70010).... (1)
SST (1)
09950-76018-71 (09950-60010).... (2)
[Point 4]
Inspection:
Inspect the caster wheel for wear.
Min. outside diameter:
A = 120 mm (4.72 in)
8-8
CASTER ARM AND CASTER LEG

T = 210 to 310 T = 148 to 222 (1,509 to 2,264) [109 to 164]
(2,141 to 3,161)
[155 to 229]
11 7
12
T = 110 to 170
(1,121 to 1,733)
3 [81 to 125]
9
10
T = 33 to 54
(337 to 551) 7
[24 to 40]
3
Removal Procedure
1 Remove the battery case W/battery.
2 Remove the floor board.
3 Remove the lock nut and bolt. [Point 1]
5 Remove the caster wheel from the caster arm. (See page 8-6.)
6 Remove the bracket. [Point 2]
7 Remove the caster arm and shaft.
8 Remove the spring and spring arm. [Point 3]
9 Remove the suspension bush. [Point 4]
10 Remove the cap and bolt.
11 Remove the snap ring.
12 Remove the caster leg and caster leg bearing from the caster arm. [Point 5]
8-9
Note:
• Apply grease on the spline before caster arm installation.
STD model: Chassis grease special
Cold storage model: Esso beacon 325
• Add grease at grease nipples (4 places) after installation.
Double nut Point Operations

T = 33 to 54 (337 to 551) [24 to 40] [Point 1]
Spring adjustment bolt
Adjustment:
(1) Please key on and off to release the swing
lock securely.
(2) Loosen the double nuts of the spring
adjustment bolt in order to adjust the free
length like the following table.
Free length
Free length mm (in)
New tire Adjustment
10 ± 0.5 (0.39 ± 0.020) 2 ± 0.5 (0.08 ± 0.020)
(3) Tighten the double nuts with 78 to 182 N·m

(796 to 1857 kgf·cm) [57.6 to 134.4 ft·lbf]
(Not necessary to apply thread tightener.)
[Point 2]
Adjustment:
Clearance When installing the bracket, insert shims as many as
needed to fill the clearance between the bracket and
frame with the bracket fit to the shaft.
Shim thickness mm (in) 0.5 (0.020)
8-10
[Point 3]
Installation:
Drive unit support
With the drive unit support roughly horizontal, install so
as to minimize the clearance between the spring stopper
and frame.
[Point 4]
Installation:
1. Fix the bracket in a vise with aluminum plates and install
the bushing using the SST.
SST (1)
SST 09950-76020-71 (09950-70010) ... (1)
09950-76018-71 (09950-60010) ... (2)
SST (2)
2. Use the SST to install the bushing.

SST 09950-76018-71 (09950-60010)
SST
SST
[Point 5]
Removal:
1. Use the SST and a hand press to remove the caster
SST (1)
leg.
SST (2)
SST 09950-76020-71 (09950-70010) ... (1)
09950-76018-71 (09950-60010) ... (2)
8-11
2. Fix the caster arm in a vise, and remove the bearing

using the SST.
SST (2) SST 09950-76020-71 (09950-70010) ... (1)
09950-76019-71 (09950-60020) ... (2)
SST (1)
Installation:
1. Use the SST and a hand press to install the bearing.
SST 09950-76020-71 (09950-70010) ... (1)
SST (1) 09950-76018-71 (09950-60010) ... (2)
SST (2), (3)
09950-76019-71 (09950-60020) ... (3)
8-12
SWING LOCK CYLINDER

Use the precoated bolt
7
T = 16.2 to 37.8
(165 to 385)
[12 to 28]
Use the precoated bolt
Removal Procedure
1 Set [ACTIVE TEST 1/1] “SWING SOL” of the analyzer from ON to OFF.
(Refer to page 4-28 in repair manual Pub. No. CE352)
2 Remove the steering wheel and instrument panel.
5 Jack up the lower part of the drive wheel.
6 Disconnect the wire harness.
7 Remove the lock pin.
8 Remove the swing lock cylinder ASSY. [Point 1]
Note:
• Apply chassis grease to the spherical portion of the upper pin before installation.
• Add chassis grease through the grease fitting after installation.
• Apply thread tightener 08833-76002-71 (08833-00080) to the threaded portions of the upper and
lower pin set bolts before tightening them.
8-13
Point Operations
[Point 1]
Inspection:
Remove the plug from the center at the tip end of the
L accumulator, and measure piston depth L of the
accumulator.
Standard : 46 mm (1.81 in) 20 °C (68 °F)
42.5 mm (1.67 in) 20 °C (68 °F)
Cold storage specification
Limit : 52 mm (2.05 in) 20 °C (68 °F)
48.5 mm (1.91 in) 20 °C (68 °F)
Cold storage specification
If the limit is exceeded, replace the swing lock cylinder
ASSY.
When tightening the plug after inspection, do not
overtighten it beyond the position in which it is flush with
the accumulator end face.
8-14
SUSPENSION SPRING
Removal Procedure
1 Set [ACTIVE TEST 1/1] “SWING SOL” of the analyzer from ON to OFF.
2 Remove the steering wheel and instrument panel.
5 Remove the suspension spring. [Point 1]

8-15
Point Operations
[Point 1]
Inspection:
When installing the mast, Perform measurement without
any load or reach operation.
Free length: 90 mm (3.54 in)
8-16
SUSPENSION SHAFT
11
13
T = 60 to 140 (612 to 1.428)

[44 to 103]
Removal Procedure
1 Remove the caster arm and caster leg. (See page 8-8.)
2 Remove the drive motor W/brake ASSY. (See page 6-6.)
4 Temporarily hoist the drive unit support. [Point 1]
5 Remove the swing lock cylinder ASSY. (See page 8-12.)
6 Remove the suspension spring. (See page 8-14.)
7 Remove the PS motor and steering gear. (See page 9-10.)
8 Remove the grease fitting from the coupling portion.
9 Extract the suspension shaft (W/collar and coupling) and bushing toward the caster arm side.
[Point 2]
10 Remove the drive unit and support. [Point 3]
11 Remove the shaft bracket and bushing.
12 Remove the suspension shaft from the drive unit side.
13 Remove the left bushing. [Point 4]

8-17
Note:
• Apply grease on the spline before caster arm installation.
• Add grease at grease nipples (4 places) after installation.
STD model: Chassis grease Special
Point Operations
SST (3)
[Point 1]
Removal:
Temporarily hoist the drive unit and support using the
SST. Rotate the drive wheel to the rear side of the
vehicle.
SST 09330-13900-71 ............................ (1)
09010-20111-71............................. (2)
SST (2) SST (1) 09090-76001-71 (09090-04020) ... (3)
[Point 2]
Removal:
Use the SST to extract the suspension shaft
(W/coupling) and bushing.
SST 09480-13900-71
(1) Screw the center bolt into the suspension shaft.
(2) Turn the nut counterclockwise and extract the
SST suspension shaft.
Installation:
Install the suspension shaft, collar and coupling.
1. Use a brass bar to install the suspension shaft. Use
the engine sling device to adjust the drive unit and
support, and drive the bushing and spline carefully to
avoid damage.
2. Install the collar.
8-18
3. When installing the coupling, fit so that the marking is

within 5 mm (0.20 in) from the horizontal position to
bring the grease hole to the frame greasing window
5 mm (0.20 in) position.
5 mm (0.20 in) Frame

greasing
window
4. Use the SST to install the suspension shaft and

bushing.
SST (2)
SST (1) SST 09310-23320-71............................ (1)
09950-76018-71 (09950-60010) ... (2)
[Point 3]
SST (3)
Removal:
Remove the drive unit and support using the SST.
Rotate the drive wheel to the rear side of the vehicle.
SST 09330-13900-71............................ (1)
09010-20111-71 ............................ (2)
09090-76001-71 (09090-04020) ... (3)
SST (2) SST (1)
SST SST
[Point 4]
Installation:
Use the SST to install the bushing.
SST 09950-76018-71 (09950-60010)
8-19
DRIVE UNIT SUPPORT

Removal Procedure
1 Remove the drive unit. (See page 7-6.)
2 Remove the caster arm and caster leg. (See page 8-8.)
3 Temporarily hoist the drive unit support by slinging with wire rope.
4 Remove the swing lock cylinder. (See page 8-12.)
5 Remove the suspension shaft. (See page 8-16.)
6 Remove the drive unit support.
7 Remove the outer race. [Point 1]

8-20
Point Operation
[Point 1]
SST Removal:
Use the SST to remove the outer race.
SST 09700-30200-71
8-21
METHOD FOR APPLYING GREASE TO SUSUPENSION
A2
IN Side
A1 A1, B1, C1
B2 OUT Side
C2 A2, B2, C2
B1
C1
A: End of the suspension shaft
B: Left side of the drive unit support
C: Right side of the drive unit support
G42808DB001_
09E_Steering.book 1 ページ２０１２年７月６日金曜日午後３時３０分
9-1
STEERING
Page
GENERAL ...............................................................9-2 NMF
SPECIFICATION .....................................................9-2 0
COMPONENTS .......................................................9-3 1
STEERING WHEEL ASSY......................................9-5 2
3
STEERING SHAFT ASSY.......................................9-7
4
5
STEERING GEAR ASSY ........................................9-10 6
DISASSEMBLY•INSPECTION•REASSEMBLY .............9-12 8
9
10
11
12
13
14
15
16
17
18
19
20
21
9-2
GENERAL
Steering wheel ASSY
Steering shaft ASSY
PS motor
Reduction device
Turn gear
G42809DA001_
SPECIFICATION
Item
Steering wheel diameter mm (in) 200 (7.9)
Steering effort N (kgf) [lbf] 4.9 (0.5) [1.1]
9-3
COMPONENTS
NMF
0
1
2
3
CA
4
CC
5
CC 6
7
8
9
CE CD 10
11
12
CB
13
G42809ZZ001_
14
11 Spiral cable BB Bearing 15
30 Washer, plate BF Cap
41 Cover, steering wheel BG Steering wheel knob
16
54 Steering torque sensor BH Main shaft 17
AF Cam BI Washer, plate
AP Ring, shaft snap BJ Cushion 18
AQ Ring, shaft snap CA Steering wheel plate set bolt
AR Ring, snap CB Screw
19
AW Screw CC Bushing 20
AY Spring, steering CD Steering wheel plate
BA Nut, steering knob set CE Plate 21
9-4
FB
FB
FA
FA
G42809ZZ002_

39 Shaft BV Pin
61 Universal joint CS spacer
71 Steering gear DO Fitting, grease
72 Housing EK Steering bracket
39A Bearing FA Bolt
39B Bearing FB Bolt
39C Seal, oil
9-5
STEERING WHEEL ASSY

NMF
0
T = 11 to 15 (110 to 155) [8.0 to 11.2] 2
1
2
3 3
T = 21 to 31 (215 to 315) [15.6 to 22.8]
4
4
5
5
6
7
8
9
10
11
Removal Procedure
1 Disconnect the battery plug. 12
2 Remove the steering wheel knob.
3 Remove the steering wheel cover. 13
4 Remove the steering wheel plate set bolt.
5 Remove the steering wheel plate. [Point 1]
14
Installation Procedure 15
The installation procedure is the reverse of the removal procedure. 16
17
18
19
20
21
9-6
Point Operations
[Point 1]
Installation:
(1) Install so that the steering spring covers the
protruded part of the main shaft.
(2) Install by inserting the protrusion of the
steering wheel plate into the groove of the
cam.
9-7
STEERING SHAFT ASSY

Note:
Carry out matching if the steering torque sensor has been removed and installed or replaced.
(Refer to “MATCHING” on page 4-45 in repair manual Pub. No. CE352.)
G42809DA002_
Removal Procedure
1 Set steering to the neutral position. [Point 1]
3 Remove the steering wheel ASSY. (See page 9-5.)
6 Disconnect the wiring.
7 Remove the steering shaft ASSY set bolt.
8 Remove the steering shaft ASSY. [Point 2]

9-8
Point Operations
[Point 1]
Removal:
Turn the steering wheel counterclockwise from the tire
straight travel position so that the notch in the drive unit
support is aligned with the match mark given on the turn
gear. (The tires are steered by approx. 10° to the right
then.) The spiral cable then is in the neutral position.
Match mark After disconnection, take measures so that the removed
G42809ZZ003_ spiral cable does not turn.
[Point 2]
Installation:
Install to the original state before removal.
• Alignment of drive unit support and turn gear
• Spiral cable neutral position
Set the spiral cable in the neutral position.

Turn it fully counterclockwise slowly and return it by 4
turns until the mark is aligned to set it in the neutral
position.
Note:
• If the cable is turned clockwise in the beginning, the
spiral cable may be reversed in the case, possibly
resulting in open circuit.
• Carefully operate so as not to apply an excessive
force. Otherwise, open circuit of the spiral cable may
be caused.
• When the steering shaft is removed for removal or
installation of the drive unit ASSY, etc., always adjust
the neutral position.
• Never change the relation between the tire neutral
position and the steering knob position.
Installation:
Apply grease to the steering gear shaft spline portion.
After reassembly, add grease through the grease fitting.
Grease
Standard model: Chassis grease special
9-9
6
5
3
2
7
1 Make match marks on the universal joint and main shaft.
2 Remove the universal joint.
3 Remove the main shaft W/steering torque sensor.
4 Disconnect the steering torque sensor connector.
5 Remove the steering bracket W/spiral cable.
6 Remove the spiral cable. [Point 1]
7 Remove the bearing.
Point Operations
[Point 1]
Set the spiral cable in the neutral position.
Turn it fully counterclockwise slowly and return it by 4 turns
until the mark is aligned to set it in the neutral position.
9-10
STEERING GEAR ASSY

G42809DA003_
Removal Procedure
2 Remove the steering shaft ASSY. (See page 9-7.)
3 Remove the PS motor.
4 Remove the suspension spring. (See page 8-14.)
5 Remove the oil seal. [Point 1]
6 Remove the steering gear ASSY. [Point 2]

9-11
Point Operations
[Point 1]
Removal:
Use a screwdriver to remove the oil seal.
Installation:
Apply grease to the oil seal lip portion.
SST 09110-30200-71
[Point 2]
Installation:
Fill grease in the gear case.
G42809DA004_
Grease
9-12
1 Remove the shaft.
2 Remove the upper bearing. [Point 1]
3 Remove the lower bearing. [Point 2]

9-13
Point Operations
[Point 1]
Inspection:
SST
Inspect the bearing and replace it if defective.
1. Remove the bearing.
SST 09950-76014-71 (09950-40011)
2. Install the bearing.

SST 09700-30200-71
SST
[Point 2]
Inspection:
Inspect the bearing and replace it if defective.
SST
1. Remove the bearing.
SST 09950-76014-71 (09950-40011)
2. Install the bearing.

SST 09700-30200-71
SST
10E_Frontbrake-axle.book 1 ページ２０１２年７月６日金曜日午後３時３１分
10-1
FRONT BRAKE & AXLE

Page
GENERAL ...............................................................10-2 NMF
SPECIFICATION .....................................................10-2 0
COMPONENTS .......................................................10-3 1
FRONT BRAKE.......................................................10-7
2
3
BRAKE VALVE........................................................10-10
4
ON-BOARD VEHICLE INSPECTION ...........................10-13 6
FRONT BRAKE AIR BLEEDING PROCEDURE ...........10-14 7
FRONT AXLE ..........................................................10-16 8
9
10
11
12
13
14
15
16
17
18
19
20
21
10-2
GENERAL
SPECIFICATION
Vehicle model
All
Item
Hydraulic internal expansion type
Foot brake type
leading trailing brake shoe (non-asbestos)
Brake drum inside diameter mm (in) Ø140 (5.51)
Material L730 (leading trailing brake shoe (non-asbestos))
Brake lining Dimensions

110 × 25 × 3.5
Length × Width × Thickness
(4.33 × 0.98 × 0.14)
mm (in)
Wheel cylinder bore mm (in) Ø17.46 (0.6874)
Oil Hydraulic oil
10-3
COMPONENTS
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
G42810ZZ001_

42 Ball, steel BD Plug
51 Brake proportional valve solenoid BE Shim 15
52 Brake shut-off solenoid BF Washer
AA Spring, compression BG Filter
16
AD Nut BH Plug 17
AF O-ring BI Plug
AG O-ring BJ Plug 18
AI O-ring BK Sleeve
AK O-ring BL Retainer 19
AL O-ring BN O-ring
AS Spring BO O-ring
20
AV Spring BP O-ring
21
AZ O-ring BQ Spool
BB Bolt
10-4
BD
G42810ZZ002_

01 Accumulator ASSY BD Valve ASSY, brake
AA O-ring
10-5
NMF
0
1
RC
2
3
RE
RA
RD RB 4
5
RE
RE 6
7
8
RE
G42810ZZ003_ 9
AC Plug LM Pipe 10
AO
BC
Bolt
Fitting
LZ
MA
Screw, breather
Cap, breather screw
11
BD Brake pipe No.1 MH 3-way 12
BF Brake pipe No.2 PZ Cover sensor
BG Hose QA Brake pipe No.3 13
CJ 2-way RA Valve ASSY, brake
DI Clip RB Bolt 14
DO Clip RC Accumulator ASSY
JO Cover RD Brake ASSY, drum
15
LL Pipe RE Bolt
16
17
18
19
20
21
10-6
AE
AL
G42810ZZ004_

10 Cylinder ASSY, wheel BH Bolt, brake set
15 Shoe set, brake CU Pin, anchor
64 Pin kit, shoe hold down DH Shoe return spring
AE Washer, spring HI Backing plate
AL Screw, breather HO Spring
BG Bolt
10-7
FRONT BRAKE
Note:
Select option set from the multifunction display DX service function before operation, and set
“ACCUM CONT” from YES to NO to stop automatic pressure accumulation. Perform air bleeding
after the end of operation. (See page 10-14.)
T = 120 to 155 (1,224 to 1,581) [88.6 to 114] T = 6.9 to 8.8 (70 to 90) [5.1 to 6.5]
9 7
T = 8 to 16 (81.6 to 163) [5.9 to 11.8]
Sensor cover
5 6
T = 7.85 to 11.77
(80 to 120)
[5.79 to 8.68] Sensor bracket
8
4 T = 8 to 16 (81.6 to 163)
[5.9 to 11.8]
3
T = 15 to 33 (153 to 337) [11 to 24]
5
2 Remove the load wheel. (See page 10-16.)
3 Remove the shoe hold spring and cup. [Point 1]
4 Remove the return spring. [Point 2]
5 Remove the brake shoe. [Point 3]
6 Remove the front speed sensor bracket.
7 Disconnect the brake pipe.
8 Remove the wheel cylinder ASSY.
9 Remove the backing plate.
Note:
Upon completing assembling, check to confirm the clearance of the front speed sensor
(See page 19-11) 0.5 to 2.5 mm (0.02 to 0.1 in).
10-8
Point Operations
[Point 1]
Disassembly:
Use the SST to remove the shoe hold spring and cup.
SST 09510-31960-71
SST
Inspection:
Measure the free length of the shoe hold spring with
vernier calipers.
Standard
Free length (reference): 15.1 mm (0.594 in)
[Point 2]
Disassembly:
Use the SST to remove the shoe return spring.
SST 09718-76001-71 (09718-20010)
SST
Inspection:
Measure the return spring thickness.
Standard
Free length (reference):
• Upper: 86.3 mm (3.398 in)
• Lower: 91.6 mm (3.606 in)
[Point 3]
Inspection:
Measure the brake lining thickness.
Standard: 3.5 mm (0.138 in)
Limit: 1.0 mm (0.039 in)
10-9
Reassembly:
Apply grease (genuine Toyota non-melt lube) on
illustrated portions (6 places in contact with shoe rim
and anchor pin) of the backing plate before installing the
brake shoe.
10-10
BRAKE VALVE
Note:
• Select option set from the multifunction display DX service function before operation, and set
“ACCUM CONT” from YES to NO to stop automatic pressure accumulation.
• Before brake valve maintenance, be sure to open the pressure relief valve to release the
residual pressure from the accumulator. Also perform air bleeding after the end of operation.
(See page 10-14.)
T = 8 to 16 (81.6 to 163) [5.9 to 11.8]
Removal Procedure
1 Remove the floor board.
2 Release the accumulator pressure. [Point 1]
3 Disconnect the pipe line. [Point 3]
4 Remove the brake valve ASSY W/accumulator ASSY.
5 Remove the accumulator ASSY. [Point 2]
6 Remove the pressure switch.

10-11
Point Operations
[Point 1]
Inspection:
(1) Accumulate pressure sufficiently in the accumulator
after material handling relief.
(2) Enter the service functions in the multifunction
display DX.
(3) Select active test in analyzer mode and operate the
brake (strongly).
(4) At the same time as you operate the brake
(strongly), start measuring the time.
(5) If the pump motor automatically starts up after no
more than 2 seconds, it is time to replace the
accumulator.
Removal:
After loosening the lock nut, loosen the screw with a
hexagon wrench.
Tightening torque for pressure releasing valve
Standard: 3.92 N·m (40 kgf·cm) [28.9 ft·lbf]
Pressure releasing valve
[Point 2]
Removal:
Since the gas in the accumulator has no color, no odor
and no toxicity, release into the open air does not cause
any problem.
Before disposal, gradually loosen the pressure
releasing plug to fully discharge the internal gas.
Pressure
releasing plug
[Point 3]
Installation:
Check the connection of the pipe lines to the brake valve
with reference of punching mark.
R port........ To the wheel cylinder right-hand
L port ........ To the wheel cylinder left-hand
T port ........ To the hydraulic oil tank
P* port ...... To the oil control valve fitting
(*P is not punched on the brake valve)
10-12
1 Remove the pressure reducing valve.
2 Remove the brake proportional valve solenoid. [Point 1]
3 Remove the brake shut-off solenoid. [Point 2]
Point Operations
[Point 1]
Inspection:
Measure the resistance with a circuit tester.
Standard: 10.3 ± 5 Ω (at 20 °C (68 °F))
[Point 2]
Inspection:
Measure the resistance with a circuit tester.
Standard: 9.95 ± 0.5 Ω (at 20 °C (68 °F))
10-13
ON-BOARD VEHICLE INSPECTION

Pressure measuring port screw size
Brake proportional G1 port PF1/8
G2 G1 solenoid valve G2 port 5/16-24 UNF
Pressure
switch
Accumulator Pressure reducing plug Pressure release plug

3.92 N·m (40 kgf·cm) [28.9 ft·lbf]
• Pressure reducing valve 1. Loosen the pressure release valve to release the pressure from the
accumulator and close it again
2. Install a pressure gauge at G2.
3. Perform tilt or lift relief and store pressure in the accumulator.
4. Check that the oil pressure is within the standard.
Standard:
kgf/cm2) [1,087.8
+0.8 +8.2 +116.0
7.5 0 MPa (76.5 0 0 psi]
5. If the standard is not satisfied, replace the pressure reducing valve.
• Pressure switch 1. Loosen the pressure release valve to release the pressure from the
accumulator and close it again.
3. Check that the oil pressure is within the standard.
Standard:
7.5 ± 0.5 MPa (76.5 ± 5.1 kgf/cm2) [1,087.8 ± 72.5 psi]
4. Set the “BRAKE L” on by the active test, and check that the pump motor
starts when the oil pressure drops to the standard value.
Standard:
5.0 ± 0.5 MPa (51 ± 5.1 kgf/cm2) [725 ± 72.5 psi]
5. Replace the pressure switch if the standard is not satisfied.
• Accumulator 1. Loosen the pressure release valve to release the pressure from the
accumulator and close it again.
3. Turn the key switch ON. After the pump motor stops, disable automatic
pressure accumulation by option setting.
4. Set the “BRAKE L” on by the active test to release pressure from the
accumulator and inspect the point where the pressure drops quickly.
Limit:
0.4 MPa or less (4.1 kgf/cm2 or less) [53.8 psi or less]
• Brake proportional solenoid valve

2. Measure the pressure upon “BRAKE L” on and “BRAKE H” on by the
active test.
Standard:
Lo: 2 ± 0.25 MPa (20.39 ± 2.55 kgf/cm2) [290 ± 36.3 psi]
Hi: 3.1 ± 0.25 MPa (31.6 ± 2.55 kgf/cm2) [449 ± 36.3 psi]
10-14
FRONT BRAKE AIR BLEEDING PROCEDURE
#3:
Pressure releasing port #4 screw

tightening torque
T = 3.92 N⋅m (40 kgf·cm) [28.9 ft·lbf]
#4:
#1: #2:
Operation Procedure
Caution:
Since the battery plug should be kept connected for this operation, chock tires before the
operation.
Never operate material handling levers during air bleeding.
1. Vehicle condition for air bleeding
Perform air bleeding after all hydraulic piping is connected and the material handling system is ready
for operation.
2. Air bleeding from the piping between the brake valve and drum brake
(1) Check that the piping between the brake valve and drum brake is connected without looseness.
(2) Check that the load tire (brake drum) is installed.
(3) Select option set from the service function on the multifunction display DX, and set “ACCUM
CONT” from YES to NO to stop automatic pressure accumulation.
(4) Perform tilt or lift relief and store pressure in the accumulator.
(5) Select active test in the analyzer mode of the service function and set “BRAKE L” from OFF to
ON to generate the brake pressure.
10-15
(6) Perform air bleeding in the following order, and tighten to the specified torque afterward.
#1 Bleeders (2 places) for brake air bleeding
[until no air bubble can be checked visually]
#2 Air bleeder (1 place)
[until discharge of air, slight dripping of hydraulic oil]
#3 Brake pressure detection and air bleeding port (1 place)
[until discharge of air, slight dripping of hydraulic oil]
(7) If hydraulic oil dripping ceases midway, set “BRAKE L” from ON to OFF to stop pressure
generation, and repeat step 2-(4) and then 2-(5) to generate pressure.
(8) After the end of air bleeding, select option set and set “ACCUM CONT” from NO to YES to enable
automatic pressure accumulation.
3. Air bleeding from the piping between control valve and brake valve
(1) Check that all hydraulic piping is connected without looseness.
(2) Select option set from the service function on the multifunction display DX and set “ACCUM
CONT” from YES to NO to stop automatic pressure accumulation.
Loosen the pressure releasing port #4 lock nut (put matchmarks between the screw and lock nut
first). Loosen the screw (counterclockwise) 1.5 turns ± 90° and release the pressure from the
accumulator. (Use a hexagon wrench to hold the screw when loosening the lock nut.)
(3) Operate the material handling lever and start the motor. Hydraulic fluid flows into the brake valve
and the air is discharged to the hydraulic fluid tank.
(4) Stop the lever operation after running the pump motor for at least 3 seconds.
(5) Tighten the pressure releasing port #4 screw 1.5 turns ± 90° and lock with the lock nut. (Use a
hexagon wrench to hold the screw when tightening the lock nut.)
(6) Perform the tilt relief and lift relief operation in order to accumulate sufficient pressure in the
accumulator.
(7) Change “ACCUM CONT” from NO to YES and activate automatic pressure accumulation.
(Following the above procedures can prevent G3 error.)
10-16
FRONT AXLE
4
2 3
T = 145 to 190 (1.479 to 1.937) [107 to 140]
G42810ZZ005_
Removal Procedure
1 Jack up the vehicle and support it with wooden blocks. (See page 0-8)
2 Remove the wheel cap.
3 Remove the lock screw.
5 Remove the load wheel. [Point 1]
6 Remove the wheel bearing. [Point 2]
Point Operations
[Point 1]
Inspection:
Measure the load wheel looseness in the axial direction.
Standard: 0.2 mm (0.0079 in) or less
10-17
Inspection :
A
Inspect the load wheel for wear.
Load tire wear limit:
A = 20 mm (0.787in) (Rubber)
A = 10 mm (0.393 in) (Urethane)
SST [Point 2]
Removal:
Use the SST to remove the load wheel.
SST 09950-76014-71 (09950-40011)
Removal:
Use the SST to remove the wheel bearing.
SST 09700-30200-71
SST
Installation:
Use the SST to install the wheel bearing.
SST (2)
SST 09950-76020-71 (09950-70010) ... (1)
SST (1) 09950-76019-71 (09950-60020) ... (2)
Inspection:
Measure the load wheel inside diameter.
Limit: 141 mm (5.55 in)
11E_Rear brake.book 1 ページ２０１２年７月６日金曜日午後３時３３分
11-1
REAR BRAKE
Page
GENERAL ...............................................................11-2 NMF
SPECIFICATIONS ...................................................11-2 0
COMPONENTS .......................................................11-3 1
REAR BRAKE .........................................................11-5 2
3
4
DISC BRAKE HEIGHT ADJUSTMENT ........................11-10
BRAKE ADJUSTING BOLT 5
AND PEDAL HEIGHT ADJUSTMENT ......................11-11 6
BRAKE LIMIT SWITCH ADJUSTMENT .......................11-12
7
INSTALLING THE DISC WHEEL ................................11-12
8
9
10
11
12
13
14
15
16
17
18
19
20
21
11-2
GENERAL
Rear Brake
Disc brake ASSY Brake disc
A Brake mounting bolt
Brake wire
Brake pedal
Disc brake ASSY

Brake disc
Brake pad
Drive motor
A-A Section view
G42811DB003_
SPECIFICATIONS
Brake type Mechanical disc brake
Brake operation type Deadman brake
Outside diameter mm (in) Ø210 (8.267)
Disc wheel
Thickness mm (in) 10 (0.39)
Area cm2 (in2) 39 × 2 (6.04 × 2)
Brake pad
Thickness mm (in) 9 (0.35)
11-3
COMPONENTS
EO NMF
AI 0
CA
BU EZ
1
BC
EY 2
AV AU
3
CG
54
AV 4
54 5
BC 49
CF
6
DL
AD 7
50
BS DX
49
8
EK
BH
FJ
BU 9
CM
DS
10
BS
CD 11
CC
AM AJ AJ 12
G42811DA001_

13
49 Cup CC Nut 14
50 Cam CD Spring washer
54 Brake pad CF Brake lever (Lower) 15
AD Brake spring CG Brake lever (Upper)
AI Cap CM Nut
16
AJ Shim DL Bolt 17
AM Pin DS Lever
AU Disc brake DX Disc brake support 18
AV Bolt EK Clip
BC Nut EO Bolt
19
BH Plate washer EY Bolt 20
BS Bushing EZ Plate washer
BU Plate washer FJ Nut 21
CA Nut
11-4
G42811ZZ001_

18 Brake wire AI Pin
20 Brake pedal AV Bolt
40 Pad AW Plate washer
41 Boot BJ Grease fitting
49 Brake pedal shaft CR Cotter pin
49A Bushing EN Bracket
AB Bolt
11-5
REAR BRAKE
T = 22 to 30 (224 to 306)
[16 to 22] NMF
7
8
0
1
T = 100 to 145
(1,020 to 1,479)
2
[74 to 107]
3
7
4
4
5
7 6
5
7
6
8
9
10
11
12
G42811DA002_
13
Removal Procedure 14
1 Remove the steering wheel and instrument panel. (See page 9-7.)
2 Remove the floor board. 15
4 Disconnect the brake limit switch harness. 16
5 Extract the clevis pin, loosen the lock nut and disconnect the brake wire. [Point 1]
6 Loosen the brake spring adjusting nut sufficiently. [Point 2]
17
7 Remove the disc brake ASSY. [Point 3]
18
8 Remove the disc wheel. [Point 4]
The installation procedure is the reverse of the removal procedure. 20
21
11-6
Point Operations
[Point 1]
Installation:
After brake ASSY installation, check brake ASSY
functioning and inspect the pedal height.
+10 +0.39
Standard : 60 0 mm (2.36 0 in)
See page 11-11 for adjustment.
[Point 2]
Removal:
Measure and record the spring installed length (A)
before loosening the brake spring adjusting nut.
Installation:
(A) Adjust the spring installed length (A) by referring to the
record made at the time of removal.
Adjust so that the pad is in close contact with the disc
wheel.
Spring installed length (A) (with a new pad)
Vehicle model Dimension A mm (in)
7FBR10,13 122 to 126 (4.80 to 4.96)
7FBR15 118 to 122 (4.65 to 4.80)
7FBR18 114 to 118 (4.49 to 4.65)
[Point 3]
Removal:
Do not lose removed shims. Record the number of
shims and places used.
Installation:
Install the shims by referring to the record made at the
time of removal.
See page 11-10 for shim adjustment.
G42811DA003_
Inspection:
Inspect the clearance between the pad and disc when
the brake pedal is depressed.
Standard: 0.2 (0.01 in) mm or more
11-7
[Point 4]
Inspection:
Inspect the disc wheel thickness.
Wear limit: 9 mm (0.35 in)
Inspection:
Inspect the disc wheel runout.
Limit: 0.1 mm (0.004 in)
G42811DB001_
11-8
T = 18 to 26 (184 to 265) [13 to 19]
4
3
6
1
5
G42811TA002_
1 Remove the brake limit switch.
2 Remove the brake spring. [Point 1]
3 Disassemble the brake lever.
4 Remove the brake pad. [Point 2]
5 Remove the brake lever and cam.
6 Remove the adjusting bolt.

11-9
Point Operations
[Point 1]
Inspection:
Inspect the free length of the brake spring.
[Point 2]
Standard pad thickness
Pad wear limit
Inspection:
Inspect the brake pad for wear.
Standard pad thickness: 9 mm (0.35 in)
Pad wear limit: 3 mm (0.12 in)
11-10
DISC BRAKE HEIGHT ADJUSTMENT
Clearance (1)
Clearance (2)
G42811DB002_
Adjustment procedure
1 Temporarily bolt the assembled disc brake to the mounting portion on top of the motor.
(Install without spring installation.)
2 Install the disc wheel on the drive motor to the specified torque.
3 Install the spring, and put the disc wheel under the brake pad.
4 In this state, insert shims to fill the clearance (1) between the brake mounting surface on top of the
motor and the disc brake support.
Shim part Nos. 0.5 mm (0.020 in)
0.2 mm (0.008 in)
5 At clearance (2), insert shims as many as at clearance (1). (In this case, manually lift the brake
support for insertion.)
6 Tighten the disc brake set bolt to the specified torque.
11-11
BRAKE ADJUSTING BOLT AND PEDAL HEIGHT ADJUSTMENT

Adjusting bolt
Cam Brake bar
97 ± 1 mm (3.82 ± 0.04 in)
Brake wire adjusting metal fixture
Adjustment procedure
1 Adjust the adjusting bolt length so that the brake bar is in the illustrated position. Carefully establish
uniform contact for the two sets of bolts and cams.
2 Adjust the brake pedal height to 70 mm (2.76 in) from the top of the floor.
3 Pump the brake pedal an appropriate number of strokes (about 10 strokes) to run in the cable.
4 After running in, depress the brake pedal fully and check to see that the clearance between the disc
wheel and brake pad is 0.2 mm (0.008 in) on top and bottom all around.
5 If the clearance is less than 0.2 mm (0.008 in), raise the brake pedal by adjusting the metal piece at
the end of the brake wire to increase the clearance to 0.2 mm (0.008 in) or more.
+10 +0.39
6 Check that the brake pedal height is in the range of 60 0 (2.36 0 in) mm.
11-12
BRAKE LIMIT SWITCH ADJUSTMENT
1. Adjust the brake pad clearance and brake pedal

height. (See page 11-10, 11-11.)
2. Adjust the mounting position so that the switch is

turned on between 1/3 and 2/3 of the brake stroke (A).
(A)
INSTALLING THE DISC WHEEL
When installing the disc wheel in the drive motor, align A

(2) with B.
(1)
(4) (1) Disc brake ASSY
(2) Disc wheel
(3) Brake pad
(4) Bolt (2 each left and right)
(1)
(A) Mark
(B) (B) Brake pad notch
(A)
(3)
G42811TA001_
12E_body.book 1 ページ２０１２年７月６日金曜日午後３時３５分
12-1
BODY
Page
DRIVER'S CAB LAYOUT CHART ..........................12-2 NMF
COMPONENTS .......................................................12-3 0
PIN CODE ENTRY SYSTEM...................................12-5 1
GENERAL ...............................................................12-5
2
COMPONENTS ........................................................12-5
3
LASER MARKER ....................................................12-7
4
GENERAL ...............................................................12-7 5
LASER LAMP ADJUSTMENT....................................12-9 6
COMPONENT PARTS AND INSTALLATION ................12-10 7
FLOOR SWITCH .....................................................12-14 8
FLOOR SWITCH INSPECTION ..................................12-14
9
FLOOR ADJUSTMENT .............................................12-14
10
REACH LEG............................................................12-15
11
12
13
14
15
16
17
18
19
20
21
12-2
DRIVER'S CAB LAYOUT CHART
9 10 11
5 1 2 3 4
G42812DA001_

1 Tilt lever 7 Steering wheel
2 Reach lever 8 Ten-key (PIN code entry system)
3 Lift lever 9 Lighting switch
4 Accelerator lever 10 Turn signal switch
5 Multifunction display DX 11 Horn switch
6 Key switch
12-3
COMPONENTS
NMF
0
1
2
3
4
5
6
7
8
9
10
AB
11
12
AA
13
14
15
16
G42812ZZ001_

17
AA
AB
Floor switch
Bolt
FE
FG
Bolt
Cushion
18
AJ Bracket FL Cushion 19
CM Plate GP Nut
CS Bushing KG Bolt 20
CT Plate KH Bolt
DH Pin UC Nut 21
DT Through bolt WV Cushion
12-4

85 Floor switch ASSY MY Arm
91 Switch PM Shaft
AR Roller PV Spring pin
ES Nut TP Bolt
FB Switch box TY Screw
JP Plate TZ Screw
JU Bushing UV Oil seal
LR Cover UW Seal
LU Spring UX Seal
12-5

GENERAL
Ten-key NMF
0
1
2
3
4
5
6
7
For an explanation of the PIN code entry system function and 8
information on how to use it, refer to the description of the “PIN CODE
ENTRY SYSTEM” on page NMF-92 of the NEW MODEL FEATURES.
G42812DA002_
9
COMPONENTS 10
11
12
1
13
2 14
15
3 4 16
5
17
8 18
7 19
6 G42812DB001_

1 Cover 5 Bracket
2 Ten-key pad 6 Plate washer 21
3 Screw 7 Nut
4 Grommet 8 Grommet
12-6
Removal Procedure
1 Open the left door and remove the nut securing the
ten-key.
Nut G42812DB002_
2 Remove the bracket.

Bracket
G42812DB003_
Ten-key 3 Remove the ten-key and remove the grommet.
Grommet
G42812DA006_
4 Remove the ten-key from the cover.

Tightening torque:
T = 0.9 to 1.1 N·m (9.2 to 11.2 kgf·cm)
[0.67 to 0.81 ft·lbf]
Note:
Be careful with the removed screws.
Cover
Ten-key
Screw
G42812DA007_
12-7
LASER MARKER
GENERAL
When the forks are close to horizontal, the laser beam shines in the direction in which the forks are inserted,
making it easier for you to check the fork height and positioning.
• You can turn the laser marker on and off using the ON-OFF switch mounted on the instrument panel.
• When the laser marker switch is set to ON, the laser marker automatically comes on whenever the forks are
close to horizontal, so you should set the laser marker switch to OFF when the laser is not required.
G42812ZZ002_
Operating Procedure
1. Stop in front of the goods to be removed and set the laser marker switch to ON.
2. Use the tilt lever to level the forks.
Note:
When the forks are close to level, the laser marker automatically comes on.
3. Use the lift lever to move the forks to the height of the goods and then, when you are close to the palette, make
fine adjustments to the fork height by watching the laser marker.
4. When you have finished moving the goods, set the laser marker switch to OFF.
Notes on Using The Laser Marker

1. Unless you are positioning the forks, set the Laser marker switch to OFF.
2. Always check that there is no-one in front of or around the vehicle before setting the laser marker switch to
ON.
3. Ensure that water does not splash directly onto the laser marker emitter.
4. Take particular care not to look directly into the laser marker or shine the laser marker directly at anyone.
5. Do not use optical instruments to look directly at the laser marker.
Note:
If any physical harm results from the use of the laser marker, immediately seek medical treatment.
12-8
Layout of Main Parts
ON
OFF
Laser marker DC/DC

converter (under the
instrument panel (LH))
Laser marker switch
Magnet switch
Laser lamp
G42812ZZ003_
12-9
LASER LAMP ADJUSTMENT

Adjustment Procedure
1. Position the forks so that their upper surfaces are horizontal. (Use a level or similar instrument.)
2. Adjust the laser lamp mounting so that the laser lamp is within the stipulated range at a distance of 700 mm
(27.56 in) from the front surface of the forks.
100
(3.9 to 200
4 to m
787 m
in):
Las
er m
arke
L mm r wi
dth
Laser marker center

Fork Level el
s f lev
max set to s i ti on o ard
imum : Po r bo
widt 5 . 91 in) r m arke
h 4 to lase
(3.9 n of
50 mm P o sitio
to 1 in):
100 7.56
0 m m (2
70
Position of laser marker center: Distance L 1.0 ton series FSV 167 mm (6.57 in) G42812ZZ004_
1.5 ton series V, SV 292 mm (11.50 in)
2.0 ton series V, SV 248 mm (9.76 in) (reference)
Laser marker adjustment width
Fork thickness at a distance of
700 mm (27.56 in) from the
front surface of the forks
5 mm (0.197 in):
100 to 200 mm (3.94 to 7.87 in):

Laser marker adjustment width
G42812ZZ005_
12-10
COMPONENT PARTS AND INSTALLATION

V Mast
Magnet
Attached to the back rest
Laser lamp switch

Attached to the lift bracket
Laser lamp unit

G42812ZZ006_
Whirlstop
screw Magnet
Bolt Use at least 1 shim.
Screw
Apply sealant 08833-00070
(08833-7600-71))
Screw
Bracket
Tightening torque: 0.2 to 0.4 N·m
(2.0 to 4.1 kgf·cm) [0.15 to 0.30 ft·lbf] Whirlstop screw Laser lamp
Apply sealant To prevent magnet rotation
(08833-00070 (08833-7600-71)) Install ahead of the magnet.
Magnet
Laser lamp
switch Plate
Bolt Bolt
Bolt Bracket O-ring
Boss
O-ring
Bolt Plate
BoltBracket G42812ZZ007_
in)
5 mm (0.197 in) 8.5 t

0.236
o
Boss (0.33 13.5 mm
5 to
(0.11 mm
0.531
8 to
in)
3 to 6
Magnet
Laser lamp Laser lamp

switch
Plate
G42812ZZ008_
Laser lamp installation standard Laser lamp and magnet installation standards
(After the laser lamp is adjusted to within the standard)
12-11
SV mast
Laser lamp
Magnet
Attached to the back rest Bolt
Laser lamp switch
Plate
Bolt
O-ring
Boss
O-ring
Bolt Plate
Laser lamp unit
G42812ZZ009_
Use at least 1 shim.
Bolt
Screw
Bracket Tightening torque:
0.2 to 0.4 N·m (2.0 to 4.1 kgf·cm)
[0.15 to 0.30 ft·lbf]
Apply sealant
Whirlstop (08833-00070 (08833-7600-71))
screw Laser lamp
switch
Bolt
Magnet
Whirlstop screw
To prevent magnet rotation
Install ahead of the magnet.
Magnet
Screw
Apply sealant (08833-00070 Bracket G42812ZZ010_
(08833-7600-71))
8.5 t
o
(0.33 13.5 mm
5 to 0
.531
5 mm (0.197 in) in)
Boss
6 in)
0.23
Magnet
(0.11 mm
8 to
6
Laser lamp
3 to
Laser lamp G42812ZZ011_

switch
Plate
Laser lamp and magnet installation standards
Laser lamp installation standard
12-12
FSV mast (1 ton series)
Bolt
Plate Bolt
Laser lamp
Laser lamp switch
Magnet O-ring
Boss
Attached to the back rest O-ring
Laser lamp unit Bolt Plate
Bracket
G42812ZZ012_
Screw
Tightening torque:
0.2 to 0.4 N·m (2.0 to 4.1 kgf·cm)
[0.15 to 0.30 ft·lbf]
Magnet Apply sealant (08833-00070
(08833-7600-71))
Bolt
Laser lamp
switch
Whirlstop screw
Screw Use at least 1 shim.

Apply sealant (08833-00070
(08833-7600-71))
Magnet
Whirlstop screw
To prevent magnet rotation
Install ahead of the magnet. Bracket
G42812ZZ013_
Boss Plate Bolt
Laser lamp
switch
Laser lamp
4 in)
Magnet
to 0.2
(0.12 mm
6
3 to
7.5 t
o
(0.30 11.5 mm
20 mm to 0.
45 in
(0.787 in) ) G42812ZZ014_
Laser lamp installation standard Laser lamp and magnet installation standards
12-13
FSV mast (2 ton series) [reference]
Magnet
Attached to the back rest
Laser lamp
Plate
Bolt
Laser lamp switch Boss
Bolt
O-ring
O-ring
Plate
Bolt
Screw Whirlstop screw

Apply sealant To prevent magnet rotation
G42812ZZ015_ (08833-00070 (08833-7600-71)) Install ahead of the magnet.
Magnet
Bracket
Laser lamp
switch
Magnet
Whirlstop screw
Screw Bolt
Tightening torque:
0.2 to 0.4 N·m (2.0 to 4.1 kgf·cm) Use at least 1 shim.
[0.15 to 0.30 ft·lbf] Bolt
Apply sealant
(08833-00070 (08833-7600-71))
Bracket G42812ZZ016_
7.5 to 11.5 mm
5 mm (0.197 in) (0.30 to 0.45 in)
Boss
(0.12 to 0.24 in)
Magnet
3 to 6 mm
Plate
Laser lamp
Laser lamp
switch G42812ZZ017_
Laser lamp installation standard
Laser lamp and magnet installation standards
12-14
FLOOR SWITCH
FLOOR SWITCH INSPECTION
1. Remove the floor.

2. Disconnect the connector.
3. Inspect the floor switch.
Note:
When removing the floor, do not hold the floor
edge portion but hold the adjusting hole portion.
Inspection 1.
Press the arm and inspect the floor switch for
A9 continuity.
Measuring position: Between floor switch
A9-1 and A9-2
Standard: When not pushed: ∞ Ω
When pushed: 0 Ω
If the standard is not satisfied, replace the floor
switch.
FLOOR ADJUSTMENT
Floor Inspection
Measure dimension B from the top of floor to the floor
mat at position A.
Reference value: B = 19 to 25 mm (0.75 to 0.98 in)
Vehicle model Dimension A
7FBR10-18 210 mm (8.27 in)
A
If the dimension at position A does not satisfy the
B
standard, adjust the floor height by turning the
adjusting bolt.
Floor Adjustment
Turn the key switch to ON. Make the following
adjustment while observing the Multifunction display
DX.
Loosen the nut and turn the adjusting bolt with a
hexagonal bar wrench.
Clockwise turn of the bolt: The floor height rises.
Counterclockwise turn: The floor height is lowered.
indication
When operator is absent “!TO OPERATING POSITION!”
When operator is
No display
present
12-15
REACH LEG
Apply grease on the on the sliding contact surface on the reach leg side to improve the durability of the carriage
roller.
Cold storage model Esso Beacom 325
1. For both LH and RH, apply grease to a width of about

60mm (2.36 in) in the center for the entire length of
dimension (1).
(2)
2. For both LH and RH, apply grease for the entire length
of portion (2).
3. For both LH and RH, apply grease for the entire length
of portion (3).
60 mm (1)
(2.36 in) Grease
(3)
Carriage roller rolling surface repair procedure

If dented or damaged or if heavily worn, clad by welding and finish with a grinder.
Welding rod: AWS A5. IE 7016 or the equivalent
After correction, make sure that the mast moves smoothly in the whole stroke.
13E_material.book 1 ページ２０１２年７月６日金曜日午後３時３７分
13-1

Page
NATURAL DROP TEST ..........................................13-2 NMF

OIL LEAK TEST ......................................................13-2 0
LIFT CYLINDER .......................................................13-2 1
TILT CYLINDER .......................................................13-3
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
13-2
NATURAL DROP TEST

13
1. Set the mast in the vertical position with the standard

load on the fork, lift the fork by 1 to 1.5 m (40 to 59 in),
and turn the key switch to OFF.
2. Draw datum lines on the inner and outer masts, and

measure the drop after 15 minutes.
OIL LEAK TEST

LIFT CYLINDER
1. Raise the fork by 1 to 1.5 m (40 to 59 in) with the

standard load on it.
2. Gradually tilt the mast fully forward, and turn the key
switch to OFF.
3. Remove the front panel and instrument panel ASSY.
4. After lapse of 5 minutes, disconnect the oil control

valve to oil tank low pressure hose from the oil tank
and fix it with its disconnected end in horizontal
position.
5. Use a lubricator to inject hydraulic oil into the low

pressure hose. Stop oil injection when oil flows out
from the end of the hose.
6. Measure the amount of oil that leaks in 1 minute.

Limit (at lift port): 8 cm3 (0.49 in3) or less
Note:
If natural drop is excessive while the amount of oil that
leaks is within the limit, the lift cylinder packing is
defective.
13-3
TILT CYLINDER
1. Set the fork level with the standard load on it, and raise
it by approx. 50 cm (19.7 in).
2. See that no oil is leaking from the reach cylinder.

NMF
3. Turn the key switch to OFF.
0
4. Remove the front panel and instrument panel ASSY.
1
5. After lapse of 5 minutes, disconnect the oil control
valve to oil tank low pressure hose from the oil tank
2
and fix it with its disconnected end in horizontal
position. 3
6. Use a lubricator to inject hydraulic oil into the low 4
pressure hose. Stop oil injection when oil flows out
from the end of the hose. 5
7. Measure the amount of oil that leaks in 1 minute. 6
Limit (total for lift and tilt): 18 cm3 (1.10 in3)
7
8. The leaking amount at the tilt port is obtained by
deducting that at the lift port from the total for lift and
tilt.
8
Note: 9
If natural drop is excessive while the amount of oil that
leaks is within the limit, the tilt cylinder packing is 10
defective.
11
12
13
14
15
16
17
18
19
20
21
14E_must.book 1 ページ２０１２年７月６日金曜日午後３時３９分
14-1
MAST
Page
V MAST ASSY ........................................................14-2 NMF
COMPONENTS ........................................................14-2 0
MAST.......................................................................14-5 1
2
3
LIFT BRACKET.......................................................14-9
MAST ADJUSTMENT (V MAST) ................................14-11 5
CHAIN .....................................................................14-20 6
INSPECTION ...........................................................14-20 7
REASSEMBLY .........................................................14-20
8
ADJUSTMENT .........................................................14-21
9
TILT HOSE ..............................................................14-21
ADJUSTMENT .........................................................14-21
10
FORK.......................................................................14-22 11
REMOVAL ...............................................................14-22 12
INSTALLATION ........................................................14-22 13
INSPECTION ...........................................................14-22 14
SV•FV•FSV MAST ASSY ........................................14-23
15
COMPONENTS ........................................................14-23
16
MAST ADJUSTMENT (SV•FV•FSV) ............................14-29
17
LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ................14-34 18
19
20
21
14-2
V MAST ASSY
COMPONENTS
6101
G42814ZZ001_
14-3
Shaft type
6301
NMF
0
1
2
3
4
5
6
7
8
Bar type
6301 9
10
11
12
13
14
15
16
17
18
19
20
21
14-4
6302
14-5
MAST
NMF
5 0
1
2 8
2
3
5
4
3
5
6
6 7
8
4
9
10
7
11
12
13
Removal Procedure
1 Move the mast forward and fully lower the fork. 14
2 Disconnect the chain. [Point 1]
3 Remove the lift bracket (raise the inner mast until it comes off the lift bracket, and remove it by 15
gradually moving the vehicle in the reverse direction).
4 Remove the hose cover. 16
5 Disconnect the tilt and lift hoses (disconnect to the hose cover portion). [Point 2]
6 Remove the reach cylinder front pin. [Point 3]
17
7 Remove the stopper bolt.
18
8 Remove the mast ASSY.
The reassembly procedure is the reverse of the disassembly procedure. 20
21
14-6
Point Operations
[Point 1]
Inspection:
Always adjust the chain tension after installation.
(See page 14-20.)
[Point 2]
Inspection:
Always adjust the hose tension after installation.
(See the page 14-21.)
[Point 3]
Disassembly:
After removing the pin, always retract the piston rod fully.
14-7
5
1
9
3 7
4 8
11
10
1 Remove the hose pulley.
2 Disconnect the overflow and high pressure hoses. [Point 1]
3 Disconnect the cylinder rod end. [Point 2]
4 Remove each cylinder support. [Point 3]
5 Remove the lift cylinders.
6 Remove the chain wheel.
7 Slide inner mast rollers downward and remove lift rollers.
8 Remove the mast strip. [Point 4]
9 Remove the inner mast.
10 Remove carriage rollers. [Point 5]
11 Remove side rollers.

14-8
Point Operations
[Point 1]
Reassembly:
After connecting each hose, temporarily tighten the hose
clamp and tighten it finally after adjusting the hose
tension.
[Point 2]
Shims
Disassembly:
Shim adjustment is made at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Shims [Point 3]
Disassembly:
Record the number of cylinder support shims in use.
Reassembly:
Perform cylinder support shim adjustment after mast or
cylinder replacement. With the cylinder rod end inserted
to the inner mast, eliminate any clearance between the
cylinder support and outer mast by inserting shim.
Shims should be slightly thicker than the clearance.
[Point 4]
Inspection:
Measure the mast strip thickness.
Limit: 1.5 mm (0.059 in)
[Point 5]
Disassembly:
SST
SST 09950-76014-71
14-9
LIFT BRACKET
2
5
1 Remove the chain.
2 Remove the tilt cylinder. [Point 1]
3 Remove the side rollers. [Point 2]
4 Remove the lift rollers. [Point 3]
5 Remove the lift bracket.
6 Remove the back rest.

14-10
Point Operations
[Point 1]
Shims Disassembly:
Record the number of inserted shims.
Reassembly:
Insert as many shims as before disassembly when
installing the tilt cylinder.
1 mm 9 mm (0.35 in)
[Point 2]
Front side
(0.039 in)
Reassembly:
Install side rollers in the correct direction.
The greater chamfering on the outside of the roller
Rounded should be on the vehicle front side.
chamfering
[Point 3]
Disassembly:
SST 09950-76014-71
SST
14-11
MAST ADJUSTMENT (V MAST)

Lift Roller Adjustment at Mast
1. Inner mast roller clearance adjustment
Inner
Outer
0 to 0.5 mm Bring into contact

(0 to 0.02 in)
(1) Adjust the mast overlap to approx. 450 mm (17.72

in).
(2) Shift the inner mast to one side to bring the roller
into contact with the outer mast, and perform shim
adjustment so that the minimum clearance between
the side face of the roller on the opposite side and
the mast satisfies the following standard:
Standard: 0 to 0.5 mm (0 to 0.02 in)
Shim thickness: 0.5•1.0 mm (0.02•0.039 in)
(3) Distribute shims equally to the left and right rollers.

(4) After adjustment, check that the inner mast moves
Shims
smoothly in the outer mast.
14-12
2. Outer mast roller clearance adjustment
Inner
Outer
0 to 0.5 mm
(0 to 0.02 in)
Bring into contact
(1) Adjust the mast overlap to approx. 450 mm (17.72

in).
(2) Shift the inner mast to one side to bring the roller
into contact with the inner mast, and perform shim
adjustment so that the minimum clearance between
the side face of the roller on the opposite side and

Shims
(4) After adjustment, check that the inner mast moves
smoothly in the outer mast.
14-13
Lift bracket roller adjustment (7FBR18 shaft type•7FBR10 to 18 bar type)
Bring into contact
0 to 0.05 mm
(0 to 0.02 in) Upper and middle
100 mm (3.94 in)
lift roller
Outer
Lift bracket
Lower lift roller

Inner
Bring into contact
0 to 0.05 mm (0 to 0.02 in)

14-14
1. Lift roller clearance adjustment

(1) Make adjustment in the position where the center of
the lift roller on top of the lift bracket is 100 mm (3.94
in) from the upper end of the inner mast.
(2) For the middle and lower lift rollers, shift the lift
bracket to one side to bring the roller into contact
with the mast, and perform shim adjustment so that
the minimum clearance between the side face of the
roller on the opposite side and the mast satisfies the
following standard:
(3) Adjust the upper roller after the middle and lower
rollers.
Bring the upper roller on one side into contact with
the mast, and perform shim adjustment so that the
minimum clearance between the side face of the
following standard:
After the clearance adjustment, use the shim and
plate for adjustment to prevent the roller from
coming off.

(5) After adjustment, check that the lift bracket moves
smoothly along the entire length of the mast.
Shims
Lower lift roller
14-15
Lift bracket roller adjustment (7FBR10 to 15)
Bring into contact
0 to 0.5 mm
(0 to 0.02 in) Upper lift roller Lift bracket
Outer
Lower lift roller

Inner
Bring into contact
0 to 0.5 mm (0 to 0.02 in)

14-16
1. Lift roller clearance adjustment

(1) Perform measurement with the lift bracket in the
uppermost position.
(2) For the lower lift rollers, shift the lift bracket to one
side to bring the roller into contact with the mast,
and perform shim adjustment so that the minimum
clearance between the side face of the roller on the
opposite side and the mast satisfies the following
standard:
(3) Adjust the upper roller after the lower roller.
Bring the upper roller on one side into contact with
the mast, and perform shim adjustment so that the
minimum clearance between the side face of the
following standard:

(5) After adjustment, check that the lift bracket moves
smoothly along the entire length of the mast.
Shims
Lower lift roller
14-17
Mast Strip Adjustment

1. Mast strip clearance adjustment
Roller
Inner mast
Outer mast
Bring into contact
0 to 0.8 mm
(0 to 0.031 in)
(1) Fully lower the inner mast.

(2) With the inner mast in contact with the outer mast
roller, perform shim adjustment so that the
clearance between the mast strip and inner mast
satisfies the following standard:
(3) After adjustment, check the mast for smooth
movement.
Shims
14-18
Mast carriage adjustment

1. Carriage roller adjustment (side-to-side)
Carriage
Leg
Bring into contact
0 to 0.5 mm (0 to 0.02 in)
(1) Perform measurement in the position where the

center of the front carriage roller is 100 mm (3.94 in)
behind the center of the reach leg load tire.
(2) No adjustment is needed for the rear carriage roller
because it is fixed with a snap ring.
(3) Shift the mast to one side to bring the roller into
contact with the mast, and perform shim adjustment
so that the minimum clearance between the side
face of the roller on the opposite side and the mast
satisfies the following standard:
(5) Install side rollers.
2. Carriage roller adjustment (up-down)
Stamped mark
2.0 mm (0.079 in) or less
Outside diameter Seal Identifi- Classifi-

(1) Bring a dial gauge into contact with the mast
No. carriage and push the roller up until the needle on
mm (in) color cation cation
1 119.7 (4.713) Black no mark the gauge reaches “0”.
Standard (2) Push the carriage down and read the needle
2 120.5 (4.744) Blue no mark
3 121.0 (4.764) Black S mark
deflection.
4 121.5 (4.783) Black M mark
Only for Standard: 2.0 mm (0.079 in) or less
supplying
5 122.0 (4.803) Black L mark
(3) If the standard is not satisfied, replace with one of
the oversize rollers listed at left.
14-19
3. Carriage side roller adjustment
100 mm (3.94 in)
(1) Perform measurement in the position where the

center of the carriage side roller is 100 mm (3.94 in)
behind the center of the reach leg load tire.
(2) Bring the side roller on one side into contact with the
reach leg.
9 mm (0.35 in) (3) Bring a dial gauge into contact with the mast
1 mm (0.039 in) carriage contact side and adjust the gauge pointer
to zero.
(4) Push the carriage toward the opposite side and read
the pointer deflection. Perform shim adjustment so
that the reading satisfies the following standard:
(5) Distribute shims equally to the front and rear and left
and right.
(6) After adjustment, check that the mast carriage
reaches smoothly.
14-20
CHAIN
SST INSPECTION
1. Inspect the chain elongation using the following

procedure:
SST 09631-22000-71
(1) Since the SST measurement scale differs according
to the chain type, set the corresponding scale on the
chain as illustrated.
(2) Check the chain No. of the chain to be inspected,
and check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it has reached the limit; replace the chain.
Chain link pitch standard

Pitch: 15.88 mm (0.63 in)
Type: BL534
Chain No.: 50
Note:
• Perform measurement without removing the chain
from the vehicle.
• Inspect elongation over the entire chain length as it
may be localized.
REASSEMBLY
1. Installing direction
Applicable
V: Lift bracket FV: Lift bracket
mast and FSV: inner mast
SV: Lift bracket FSV: Lift bracket
section
Center of the Center of Center of

vehicle the vehicle the vehicle
Rough
sketch
Cotter pin Cotter pin Cotter pin
Install the chain with the Install the chain with the Install the chain with the
cotter pin facing the center cotter pin facing the center cotter pin facing the front
of the vehicle. of the vehicle. side of the vehicle.
14-21
2. Chain adjusting nut tightening procedure

(1) Tighten nuts [1] and [2]. T = 50.0 to 78.0 N·m (500 to 800 kgf·cm) [36.2 to 57.9 ft·lbf]
(2) Tighten nut [3].
V: Outer mast
Applicable mast SV: Outer mast
FSV: Outer mast
and section FV: Front cylinder section
FSV: Front cylinder section
clamp
Rough sketch
ADJUSTMENT
1 Park the vehicle on level ground. Tilt the mast backward to tilt the fork backward, and level the fork
after checking the lift cylinder rod is at the lowermost position.
2 Make adjustment by the adjusting nut to eliminate chain slackness.
3 Check to see that the chain tension is equal on the left and right sides.
4 Check that the chain is not twisted.
5 Check that the lifting height meets the standard.
6 In the uppermost position, check that the lift bracket fall-out prevention stopper at the inner mast
upper beam is not in contact with the lift bracket.
TILT HOSE
ADJUSTMENT
1 Lift the fork to 10 to 20 mm (0.39 to 0.79 in) from the

ground.
2 Inspect by manually pushing and pulling the center of
the hose.The hose is normal if it is not twisted and its
tension is appropriate.
3 Loosen the hose clamp before hose tension
adjustment.
After adjustment, tighten the clamp set bolt securely.
14-22
FORK
REMOVAL
Finger bar type:

1 Set the mast in the maximum reach position.
2 Set the fork at approx. 20 cm (7.87 in) above the
ground.
3 Place a wooden block under the notched section of the
fork rail.
4 Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
5 Slowly lower the fork for removal.
Fork shaft type:

1 Set the mast in the maximum reach position.
2 Lower the fork fully.
3 Sling the back rest with a wire and hoist it slightly
without hoisting the fork.
4 Remove the shaft stopper set bolt and remove the shaft
stopper plate.
5 Drive the fork shaft out and remove the fork.
INSTALLATION

procedure.
INSPECTION
1 Inspect misalignment of the fork tip ends.

If the limit is exceeded, inspect individual fork bend,
looseness of fork installation and lift bracket finger bar
distortion.
14-23
SV•FV•FSV MAST ASSY

COMPONENTS
SV
6101
G42814ZZ002_
14-24
FV
6101
G42814ZZ003_
14-25
FSV
6101
14-26
SV
Shaft type Bar type 6301
FV
14-27
FSV
SV
6302
14-28
FV
6302
FSV
6302
14-29
MAST ADJUSTMENT (SV•FV•FSV)

Lift Roller Adjustment at Mast
1. Inner mast roller (SV·FV·FSV) and middle mast lower roller (FSV) clearance adjustment
Inner
Outer
0 to 0.5 mm
(0 to 0.02 in)
Bring into contact
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the mast, and perform shim
adjustment so that the minimum clearance between the roller side face on the opposite side and
(4) After adjustment, check that mutual mast movement is smooth.
14-30
2. Outer mast roller (SV·FV·FSV) and middle mast upper roller (FSV) clearance adjustment
Inner
Outer
0 to 0.5 mm
(0 to 0.02 in)
Bring into contact
(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and perform
shim adjustment so that the minimum clearance between the roller side face on the opposite side
and the mast satisfies the following standard:
Sim thickness: 0.5•1.0 mm (0.02•0.039 in)
(4) After adjustment, check that mutual mast movement is smooth.
14-31
Lift and Side Roller Adjustment at Lift Bracket

1. SV mast
0 to 0.5 mm Middle lift roller

(0 to 0.02 in)
Side roller Bring into contact
Lower lift roller
0 to 0.5 mm
(0 to 0.02 in)
Bring into contact
R1
100 mm (3.94 in)
Outer
Lift bracket
Inner
G42814ZZ004_
(1) Position the center of the side roller on top of the lift bracket at 100 mm (3.94 in) from the top of
the inner mast.
(2) No adjustment is needed for the upper lift roller because it is fixed with a snap ring.
(3) Shift the lift bracket to one side to bring the middle lift roller into contact with the mast, and
perform shim adjustment so that the clearance between the roller side face on the opposite side
and the mast satisfies the following standard:
Shim thickness: 0.5•1.0 mm (0.02•0.039in)
(5) After the inspection and adjustment in step (3) above, inspect and adjust the upper and lower
side rollers.
Bring the side roller on one side into contact with the mast side face, and perform shim
adjustment so that the clearance between the side roller on the opposite side and the inner mast
side face satisfies the following standard:
Shim thickness: 0.5•1.0 mm (0.02•0.039in)
(6) If the standard is not met, adjust by changing the shim thickness. (Distribute shims equally to the
left and right side rollers.)
(7) After adjustment, check that the lift bracket moves smoothly along the entire length of the mast.
14-32
2. FSV•FV mast
0 to 0.5 mm Upper lift roller

(0 to 0.02 in)
Lower lift roller
Bring into contact
0 to 0.5 mm
(0 to 0.02 in)
Lift bracket
(1) Set the lift bracket at the uppermost position.

(2) Shift the lift bracket to one side to bring the roller into contact with the mast, and perform shim
adjustment so that the minimum clearance between the roller side face on the opposite side and
(4) Inspect and adjust the upper lift rollers after the inspection and adjustment in step (2).
(5) Bring the lift roller on one side into contact with the mast, and perform shim adjustment so that the
clearance between the side roller and the inner mast side face satisfies the following standard:
(7) After adjustment, check that the lift bracket moves smoothly along the entire length of the mast.
14-33
Mast Strip Adjustment

1. Mast strip clearance adjustment
Roller
Inner mast (Middle mast)
0 to 0.8 mm
(0 to 0.03 in)
Outer mast (Middle mast)
(1) Lower the inner (or middle) mast fully.

(2) With the inner mast (middle mast) in contact with the outer mast roller (middle mast upper roller),
perform shim adjustment so that the clearance between the mast strip and the mast satisfies the
following standard:
(3) After adjustment, check the mast for smooth movement.
14-34
LIFT CYLINDER ROD SHIM ADJUSTMENT

(PREVENTION OF UNEVEN LIFTING)
Note:
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on
the left and right sides due to tolerances of parts, etc.
• Perform inspection and adjustment when any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod, lift cylinder, mast ASSY, outer mast, and inner mast.
• After adjustment, perform TBC•EPS matching.
(Refer to "MATCHING" on page 4-45 in repair manual Pub. No. CE352.)
1. Inspection method
Slowly lift the inner mast, and check the stopping state
of the cylinder rods LH and RH when the inner mast
reaches the uppermost position.
(1) Normal case
Both the left and right rods stop almost
simultaneously with almost no shaking of the inner
mast.
(2) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping.To
correct this, add shims to the cylinder that stops
first.
2. Adjustment method
SST (1) Raise the inner mast, attach the SST to the outer
mast tie beam, and lower the inner mast until it
comes into contact with the SST.
SST 09610-22000-71
(2) Remove the cylinder rod end set bolt on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end, and slowly

raise the cylinder rod end into the inner mast.
Shims (5) Install the set bolt cylinder rod end set bolt.
(6) Raise the inner mast again for reinspection.
(7) Repeat the inspection and adjustment until the
number of shims is determined.
15E_cylinder.book 1 ページ２０１２年７月６日金曜日午後３時４１分
15-1
CYLINDER
Page Page
LIFT CYLINDER (V•SV)•REAR TILT CYLINDER...................... 15-24 0
LIFT CYLINDER (FV•FSV) .....15-2 GENERAL .............................. 15-24 0
GENERAL.................................15-2
SPECIFICATIONS .................... 15-24 1
SPECIFICATIONS ......................15-4
COMPONENTS ....................... 15-25 2
COMPONENTS .........................15-5
REMOVAL•INSTALLATION ....... 15-26
3
REMOVAL•INSTALLATION .........15-7 DISASSEMBLY•INSPECTION•
DISASSEMBLY•INSPECTION• REASSEMBLY ...................... 15-27 4
REASSEMBLY ........................15-9 5
TILT ANGLE ADJUSTMENT .....15-29
FLOW REGULATOR VALVE
8
(V•SV•FV•FSV)......................15-11
REMOVAL•INSTALLATION .......15-12
7
SAFETY DOWN VALVE 8
(V•SV•FV•FSV)......................15-13 9
10
FRONT LIFT CYLINDER
(FV•FSV) ...............................15-15 11
GENERAL...............................15-15 12
SPECIFICATIONS ....................15-15 13
COMPONENTS .......................15-16 14
15
DISASSEMBLY•INSPECTION•
REASSEMBLY ......................15-17 16
REACH CYLINDER ................15-19 17
GENERAL...............................15-19 18
SPECIFICATIONS ....................15-19 19
COMPONENTS .......................15-20
20
21
DISASSEMBLY•INSPECTION•
REASSEMBLY ......................15-22
15-2
LIFT CYLINDER (V•SV)•REAR LIFT CYLINDER (FV•FSV)

15
GENERAL
Lift Cylinder (V•SV Mast)
RH
LH
Rear Lift Cylinder (FV Mast)
RH
LH
15-3
Rear Lift Cylinder (FSV Mast)
RH
NMF
0
1
LH
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
15-4
SPECIFICATIONS
Lift Cylinder (V•SV)
Cylinder type Single-acting type
Cylinder bore mm (in) 45 (1.77)
Piston rod outside diameter mm (in) 35 (1.38)
Piston seal type U packing
Rod seal type U packing
Built-in flow regulator valve (RH)
Others
Built-in safety down valve (LH)
Rear Lift Cylinder (FV)

Built-in flow regulator valve (RH)
Others
Built-in safety down valve (LH)
Rear Lift Cylinder (FSV)

Others Built-in safety down valve (RH)
15-5
COMPONENTS
Lift Cylinder (V•SV)
6501
NMF
0
1
2
3
4
5
6
7
8
Rear Lift Cylinder (FV)
9
6503
10
11
12
13
14
15
16
17
18
19
20
21
15-6
Rear Lift Cylinder (FSV)

6503
15-7
2
T = 50 to 90 (510 to 920)
[36.9 to 66.5]
9
6
Removal Procedure
1 Fully lower the fork.
2 Remove the cylinder rod end set bolt.
3 Hoist the inner mast by slinging with a wire, and disconnect the lift cylinder rod end. [Point 1]
4 Hoist the inner mast until the lift cylinder ASSY can be removed toward the front side of the vehicle.
5 Disconnect hoses.
6 Remove the lift cylinder support. [Point 2]
7 Remove the lift cylinder bottom set bolt.
8 Remove the lift cylinder ASSY.
9 Use the SST to hold the mast to prevent it from falling down. [Point 3]
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat no-load full-stroke lifting and lowering to check normal operation while
bleeding air.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect the lift cylinders LH and RH for uneven lifting and adjust them as needed.
(See page 14-34.)
15-8
Point Operations
[Point 1]
Removal:
Shims Shim adjustment at the lift cylinder rod end has been
performed to prevent uneven lifting by lift cylinders LH
and RH. Record at which cylinder the adjustment is
made and also the number of shims used.
[Point 2]
Installation:
Temporarily fasten the cylinder support, and eliminate
Shims any clearance between the cylinder support and outer
mast by shim insertion after connecting the rod end.
(The shim thickness should be slightly greater than the
clearance.)
[Point 3]
SST SST 09610-22000-71
15-9
2 2
4
4
3 3
5
5
1
1 Remove the flow regulator valve or safety down valve.
2 Remove the cylinder cover.
3 Remove the rod guide.
4 Remove the piston rod. [Point 1]
5 Remove seals on the piston side.
6 Remove the lift cylinders. [Point 2]
Note:
• Apply MP grease or hydraulic oil to packings, o-rings and dust seal lips.
• Apply sealant 08833-00080 (08833-76002-71) to the threaded portion of the cylinder cover
before tightening.
15-10
Point Operations
[Point 1]
Inspection:
Measure the piston rod outside diameter.
V·SV·FSV
Limit: 34.92 mm (1.375 in)
FV
Limit: 31.92 mm (1.275 in)
[Point 2]
Inspection:
Measure the lift cylinder bore.
Limit: 45.20 mm (1.780 in)
15-11
FLOW REGULATOR VALVE (V•SV•FV•FSV)
Lowering Speed Specifications

mm/sec (fpm)
Mast
V SV FV FSV
No-load 550 (108) I 400 (79) 420 (83)

Load 500 (98) I 450 (89) 450 (89)
15-12
Note:
• The explanation here is for the flow regulator valve for the V, SV or FV mast.
• In the case of the FSV mast, the flow regulator valve is installed on the outer mast.
3
T = 58.8 to 68.6 (600 to 700) [43.4 to 50.6]
Removal Procedure
1 Disconnect the cylinder rod end and hoist the inner mast. [Point 1]
2 Loosen the cylinder support bolt, and disconnect the piping.
3 Rotate the cylinder by about 90° counterclockwise, and remove the flow regulator valve.
Point Operations
[Point 1]
SST
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the SST.
SST 09610-22000-71
15-13
SAFETY DOWN VALVE (V•SV•FV•FSV)

Safety Down Valve Section (for V•SV) (for FV•FSV Rear Lift Cylinder)
V•SV•FV FSV
Safety Down Valve Section (for FV•FSV Front Lift Cylinder)

15-14
2
T = 53.9 to 68.6 (550 to 700) [39.8 to 50.6]
Removal Procedure
1 Hoist the inner mast. [Point 1]
2 Remove the safety down valve.
Point Operations
[Point 1]
SST
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and lower
the inner mast until it comes into contact with the SST.
SST 09610-22000-71
15-15
FRONT LIFT CYLINDER (FV•FSV)

GENERAL
Front Lift Cylinder (FV•FSV)
SPECIFICATIONS
Others Built-in safety down valve
15-16
COMPONENTS
6502
Removal Procedure
1 Disconnect the chain.
2 Disconnect the hoses.
3 Remove the cylinder set bolts.
4 Remove the lift cylinders.
Note:
After installing the lift cylinder, follow the steps below.
1. Repeat no-load full-stroke lifting and lowering to check normal operation while
bleeding air.
2. Check the hydraulic oil level and add if insufficient.
3. Adjust the lift chain tension equally on the left and right sides.
15-17
2
6
1 Remove the chain wheel supporter.
2 Remove the cylinder rod guide.
4 Remove the wear ring and U packing.
5 Remove the check valve.
6 Remove the lift cylinders. [Point 2]
7 Remove the safety down valve.
Note:
• Apply MP grease or hydraulic oil to packings, o-rings and dust seal lips.
• Apply sealant 08833-00080 (08833-76002-71) to the threaded portion of the rod guide before
tightening.
15-18
Point Operations
[Point 1]
Inspection:
Limit: 49.92 mm (1.9654 in)
Inspection:
Measure the bend of the piston rod.
Limit: 2.0 mm
[Point 2]
Inspection:
Measure the lift cylinder bore.
Limit: 70.35 mm (2.7697 in)
15-19
REACH CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double-acting type
Piston seal type O-ring
15-20
COMPONENTS
15-21
6 1
5 4
Removal Procedure
1 Push the mast (reach) fully forward.
2 Extract the reach cylinder front pin.
3 Operate the reach lever to retract the cylinder rod.
4 Disconnect the reach hose (piping).
5 Remove the cylinder bracket.
6 Remove the cylinder ASSY.
15-22
1•5
1 Loosen the rod guide. [Point 1]
2 Extract the piston W/rod guide. [Point 2]
3 Remove the reach cylinder. [Point 3]
4 Remove the piston from the piston rod.
5 Remove the rod guide from the piston rod.
15-23
Point Operations
[Point 1]
Disassembly•Reassembly:
SST 09620-10100-71
[Point 2]
Disassembly:
Extract the rod carefully in a parallel direction from the
cylinder so as not to damage the rod or cylinder.
[Point 3]
Inspection:
Measure the cylinder bore.
Limit: 45.35 mm (1.79 in)
[Point 4]
Inspection:
Limit: 24.92 mm (0.9811 in)
Inspection:
Limit 2.0 mm (0.079 in)
15-24
TILT CYLINDER
GENERAL
SPECIFICATIONS
V mast SV, FV, FSV mast
Cylinder type Double-acting type
Number of cylinders 2
Cylinder bore mm (in) 50 (1.97) 55 (2017)
Piston stroke mm (in) 47 (1.85) 36 (1.42)
Piston seal type O-ring
15-25
COMPONENTS
6511
15-26
T = 490.4 (5000)
[361.7]
4 T = 30 to 38
(305 to 390)
[22.1 to 28.2]
Removal Procedure
1 Move the mast fully forward.
2 Raise the fork by approx. 1 m and fully tilt the mast forward.
4 Disconnect the tilt hose (piping).
5 Remove the tilt cylinder ASSY.
Note:
• After installation, slowly tilt the mast forward and backward a few times to check normal
functioning.
• Check the hydraulic oil level and add if insufficient.
15-27
2 4
1 Remove the rod guide. [Point 1]
2 Extract the piston rod W/piston. [Point 2]
3 Remove the tilt cylinder. [Point 3]
4 Disassemble the piston portion of the piston rod. [Point 4]
Note:
• Apply‚ MP grease or hydraulic oil on packings, o-rings and dust seal lips.
• Apply sealant 08833-00080 (08833-76002-71) to the threaded portion of the rod guide before
reassembly.
15-28
Point Operations
[Point 1]
SST 09620-10100-71
[Point 2]
Disassembly:
Blow air in through the cylinder piping port for easy
removal.
[Point 3]
Inspection:
Measure the cylinder bore.
V
Limit: 50.35 mm (1.98 in)
SV•FV•FSV
Limit: 55.35 mm (2.18 in)
[Point 4]
Inspection:
Limit: 24.92 mm (0.9811 in)
Inspection:
Limit: 0.5 mm (0.02 in)
15-29
TILT ANGLE ADJUSTMENT

Adjust the tilt angle by shim adjustment at the tilt cylinder installation location. Adjustment in the fork
downward direction, however, is impossible.
1 Perform shim adjustment so that the fork upward tilt angle is within the standard when the tilt cylinder
is fully extended.
Distribute shims equally at the upper and lower sides.
Tilt angle standard (fork upward tilt angle): 5° ± 48'

Thickness mm (in) Place used
1.0 (0.039) Lower side of RH and upper side of LH
0.5 (0.02) Lower side of RH and upper side of LH
1.0 (0.039) Upper side of RH and lower side of LH
0.5 (0.02) Upper side of RH and lower side of LH
2 Check that there is clearance between the tip end of the tilt cylinder rod and the finger bracket tilt
protector (A portion) when the tilt cylinder is fully retracted.
16E_oil pump.book 1 ページ２０１２年７月６日金曜日午後３時４３分
16-1
OIL PUMP
Page
GENERAL ...............................................................16-2 NMF
SPECIFICATIONS ...................................................16-2 0
COMPONENTS .......................................................16-3 1
OIL PUMP ASSY.....................................................16-4 2
3
4
TEST METHOD .......................................................16-7
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
16-2
GENERAL
16
Single Gear Pump
SPECIFICATIONS
Oil pump name Single gear pump
Oil pump type TMGIA16F9H5-R190
Drive system Direct motor drive
Discharge (pump at 1500 rpm) l/min 23.4
Theoretical discharge cc/rev 16.7
16-3
COMPONENTS
6701
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
16-4
OIL PUMP ASSY

Removal Procedure
2 Remove the instrument panel and charger panel.
(See page 2-8.)
3 Remove the center panel. (See page 2-12.)
4 Disconnect the inlet and outlet hoses.

5 Remove the oil pump set bolts.
Inlet hose
Outlet hose
G42816DA001
6 Remove the oil pump ASSY.

7 Remove the fitting.
G42816DA002
The installation procedure is the reverse of the
removal procedure.
Note:
• Apply grease to the spline section of the oil
pump ASSY before installation.
• Clean the fitting-mounting surface so as not to
damage the o-ring.
16-5
5
NMF
0
1
2
3
6
4
5
6
7
3 8
4 9
Disassembly Procedure 10
1 Make match marks between the front cover and body and between the rear cover and body.
[Point 1] 11
2 Fix the front cover facing downward and remove the bolts.
3 Remove the rear cover ASSY. 12
4 Remove the body and side plate. [Point 2]
5 Remove the drive gear, driven gear and side plate. [Point 3]
13
6 Remove the oil seal. 14
15
Note: 16
• Wash each part, blow compressed air and apply hydraulic oil before installation.
• Always use new seals for reassembly. 17
18
19
20
21
16-6
Match mark between front Match mark between Point Operations

cover and body rear cover and body [Point 1]
Disassembly:
Make match marks between the front cover and body
and between the rear cover and body.
Reassembly:
Align match marks when reassembling.
Front cover Body Rear cover
Wear limit: 0.15 mm (0.006 in) or less [Point 2]

Strong Inspection:
LBC surface contact
(yellow) around here The side plate surface (LBC surface) in contact with
gears should not be worn beyond the limit shown at left.
Suction
Discharge
port
port
Erosion by cavitation
around this portion
Inspection:
Wipe mark depth Inspect the body inner surface for the wipe mark.
0.01 to 0.06 (0.00039 to 0.0024)
Normal wipe depth: 0.01 to 0.06 mm
Suction port (0.00039 to 0.0024 in)
Discharge
port
Wipe mark
[Point 3]
Disassembly:
Make match marks on the tooth flanks of the drive and
driven gears.
Drive gear Reassembly:
Driven gear
Align match marks when reassembling.
Front cover
Inspection:
Check the gear side surface for wear and the tooth
flanks for roughening.
Shaft diameter limit: 21.997 mm (0.87 in)
Facewidth limit: 19.3 mm (0.76 in)
Shaft diameter
-
ce
F a th
d
wi
16-7
TEST METHOD
A bench test should be conducted for strict testing, but as it is generally impossible in practical service
operation, install the oil pump on the vehicle and judge the oil pump discharge performance by means of
cylinder operation.
• Check that the battery charge is sufficient by observing the battery charge indicators.
• Check that the oil control valve set relief pressure is as specified. (See page 17-12.)
• Measure the lift cylinder full stroke operation time when the hydraulic oil temperature is 50 to 55°C
(122 to 131°F), and calculate the lifting speed.
Because of the soft start by the material handling chopper circuit, the lifting speed is 10 to 20 mm/sec
(2.0 to 3.9 fpm) lower than the value obtained from the table below. The precision of the lifting speed,
therefore, is higher if measured excluding the soft start period.
The lifting speed depends slightly on the battery, hydraulic oil temperature and mast adjustment.
The value below is for the case where given conditions are satisfied.
Lifting Speed Table
mm/sec (fpm)
V•SV mast FV mast FSV mast
Vehicle
Lifting speed Lifting speed Lifting speed
model
No-load Loaded No-load Loaded No-load Loaded
7FBR10 540 (106) 350 (69) 480 (94) 290 (57) 480 (94) 290 (57)
7FBR13 K 320 (63) K 270 (53) K 270 (53)
7FBR15 K 310 (61) K 280 (55) K 280 (55)
7FBR18 K 300 (59) K 270 (53) K 270 (53)
17E_oil control.book 1 ページ２０１２年７月６日金曜日午後３時４５分
17-1
OIL CONTROL VALVE

Page
GENERAL ...............................................................17-2 NMF
SPECIFICATIONS ...................................................17-6 0
COMPONENTS .......................................................17-7 1
OIL CONTROL VALVE ASSY.................................17-9
2
3
RELIEF PRESSURE ADJUSTMENT......................17-12
4
MATERIAL HANDLING LEVER SWITCH 5
ADJUSTMENT ......................................................17-13 6
LIFT LOCK UNLOCKING BOLT.............................17-14
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
17-2
GENERAL
17
Lever layout (as seen from the Operator's Seat)
T: Tilt, R: Reach, L: Lift, A: Attachment

Lever layout
Three levers T•R•L
Four levers A•T•R•L
Four levers (without tilt) A•A•R•L
Five levers A•A•T•R•L
A thick frame shows the STD.
Oil Control Valve

17-3
Oil Control Valve Sectional View
NMF
0
Lift 1
2
3
Reach
4
5
Tilt
6
7
8
9
Lift Block Sectional View 10
11
12
13
14
15
16
17
18
19
20
21
17-4
Tilt Block Sectional View
Reach Block Sectional View

17-5
Relief Valve Sectional View
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
17-6
Hydraulic Circuit Diagram
T P
(Lift)
C1
(Reach)
C2
C3
(Tilt)
C4
C5
SPECIFICATIONS
Vehicle model
7FBR 10•13 7FBR 15•18
Item
Type Add-on type
Relief pressure MPa (kgf/cm2) [psi] 12.2 (125) [1780] 16.8 (170) [2420]
Others Built-in lift and tilt lock valves
17-7
COMPONENTS
6705
6705
17-8
6709
17-9
OIL CONTROL VALVE ASSY

Note:
Before starting removal, operate material handling levers to push the mast out forward and lower
the fork fully so as to eliminate residual pressure in the material handling system piping.
4 3
Removal Procedure
3 Remove the steering wheel ASSY. (See page 9-5.)
5 Disconnect the piping and wiring.
6 Remove the valve bracket set bolts.
7 Remove the oil control valve W/bracket.
8 Remove the oil control valve ASSY.
Note:
• Adjust the material handling lever switch after installing the oil control valve ASSY.
(See page 17-13.)
• Apply grease to oil control valve lever linkage.
• Check the hydraulic oil level, and add if insufficient.
• Perform air bleeding after installing the oil control valve. (See page 10-14.)
17-10
Note:
• As parts are finished with high precision, carefully disassemble and reassemble to prevent any
damage.
• Choose a clean location for the job.
3
6
5
1 Remove the control valve lever.
2 Remove the material handling lever switch. [Point 1]
3 Separate each valve block. [Point 2]
4 Disassemble the lift spool block. [Point 3]
5 Disassemble the reach spool block. [Point 4]
6 Disassemble the tilt spool block. [Point 5]
7 Remove the relief valve. [Point 6]
Note:
• Wash each part thoroughly, blow compressed air and apply hydraulic oil before reassembly.
• Fully loosen the relief valve adjusting screw before reassembly.
17-11
30°
Point Operations
[Point 1]
Reassembly:
Adjust the material handling lever switch position and
install it.
Adjust so that the material handling lever switch is
turned on immediately when the spool starts to move in
response to lift lever operation. (See page 17-13.)
[Point 2]
Reassembly:
The fitting angle should be as illustrated for reassembly.
20°
20°
20°
SST [Point 3]
Use the SST to disassembly•reassembly the spool
spring.
SST 09610-10161-71
[Point 4] [Point 5]
See [Piont 3] for spool spring disassembly and
reassembly.
[Point 6]
Reassembly:
Always loosen the adjusting screw fully when the relief
valve is disassembled.
Relief valve
17-12
RELIEF PRESSURE ADJUSTMENT

Note:
• Always follow the procedure below for adjustment. Careless adjustment may damage
hydraulic units, such as the oil pump, due to high pressure generation.
• No adjustment is needed when the relief valve is not disassembled or is replaced with a new
one.
Relief valve
P port fitting
1 Disconnect the brake piping and brake piping adapter from the oil control valve P port fitting and
install an oil pressure gauge.
2 Loosen the relief valve adjusting screw.
Loosen the lock nut, and loosen the adjusting screw to a degree at which it does not come off from
the body.
3 Adjust the oil pressure as follows:
(1) Turn the key switch to ON.
(2) Slowly operate the lift lever in the lifting direction, and gradually tighten the adjusting screw until
the fork starts to rise.
(3) Lift the fork fully and read the oil pressure at that position.Tighten the adjusting screw so that the
oil pressure then is set to a normal value.
(4) Tighten the lock nut and re-check the oil pressure.
Caution:
If the specified pressure is exceeded during adjustment, immediately return the lever to the
neutral position.
Relief Pressure Standards

MPa (kgf/cm2) [psi]
7FBR 10•13 7FBR 15•18
Relief pressure 12.2 (125) [1780] 16.8 (170) [2420]
4 Remove the oil pressure gauge, and install the brake piping adapter and brake piping.
5 Perform air bleeding from the brake piping. (See page 10-14.)
*The relief pressure can be checked by analyzer [I/O TRAVELING 2/5] “SPLF”.
17-13
MATERIAL HANDLING LEVER SWITCH ADJUSTMENT

1 Adjust the material handling lever switch (front)
A mounting position so that it is turned off in the range of
A between 10 and 20 mm (0.39 and 0.79 in) from the
fully pulled position.
B
2 Adjust the material handling lever switch (rear)
mounting position so that it is turned on in the range of
B between 5 and 10 mm (0.20 and 0.39 in) from the
position where the lift lever play is eliminated.
17-14
LIFT LOCK UNLOCKING BOLT

Lift lock unlocking bolt

T = 1.49 to 1.83 (15 to 19)
[1.08 to 1.37]
If the fork does not come down due to solenoid valve defect or other reason, loosen the lock nut and the
lift lock unlocking bolt, and operate the lift lever in the lowering direction to enable manual fork lowering
as an emergency action.
Always return the bolt to its original position after repair. Failure to return to the original position
causes relief of the hydraulic oil from the oil pump, making operation difficult due to extremely
slow lifting speed.
Caution:
Be sure to reach out the mast and disconnect the battery plug before unlocking the lift lock.
18E_hydro.book 1 ページ２０１２年７月６日金曜日午後３時４７分
18-1
HYDRAULIC PIPING
Page
GENERAL ...............................................................18-2 NMF
SPECIFICATIONS ...................................................18-2 0
OIL FILTER .............................................................18-2 1
OIL TANK................................................................18-3
2
COMPONENTS .......................................................18-4
3
BODY PIPING COMPONENTS ..................................18-4
MAST PIPING COMPONENTS...................................18-5
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
18-2
GENERAL
18
Lift cylinder
Oil control valve
Suction filter
Tilt cylinder Pump motor
Oil pump Oil tank
Reach cylinder Return filter
SPECIFICATIONS
OIL FILTER
Type Wire mesh type
Suction filter Filtering precision 40 mesh
Filtering area 188 cm2 (29.1 in2)
Type Full-flow type
Return filter Filtering precision 30 μm (0.0012 in)
Filtering area Approx. 2,000 cm2 (310 in2)
18-3
OIL TANK
NMF
0
T = 6 to 10
(61.2 to 102.0)
[4.43 to 7.38] 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
18-4
COMPONENTS
BODY PIPING COMPONENTS
6804
18-5
MAST PIPING COMPONENTS

6805
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
19E_SAS R.book 1 ページ２０１２年７月６日金曜日午後３時４９分
19-1
TBC•EPS
Page
GENERAL ...............................................................19-2 NMF
COMPONENTS .......................................................19-3 0
SPEED SENSOR (DRIVE MOTOR).............................19-3 1
STEERING TORQUE SENSOR ..................................19-3
2
FRONT SPEED SENSOR, LOAD SENSOR .................19-4
3
TIRE ANGLE SENSOR .............................................19-4
LIFTING HEIGHT SWITCH (FOR FV AND FSV MAST)..19-5
4
LIFTING HEIGHT SWITCH (FOR V AND SV MAST) .....19-5 5
FOR REPAIR WORK...............................................19-6 6
MATCHING..............................................................19-7 7
CAUTION FOR VEHICLE ALTERATION................19-7 8
TIRE ANGLE SENSOR ...........................................19-8
9
10
LOAD SENSOR ......................................................19-10
11
FRONT SPEED SENSOR .......................................19-11 12
SPEED SENSOR (DRIVE MOTOR)........................19-12 14
LIFTING HEIGHT SWITCH .....................................19-13 16
17
18
STEERING TORQUE SENSOR ..............................19-16
19
21
19-2
GENERAL
TBC (Traction and Brake Control) and EPS (Electric Powered Steering) Configuration
TBC
Sensors and switches installed in each section of the vehicle send vehicle movement signals to the
controller. These signals are then used for controlling the drive motor, brake valve and swing lock
cylinder.
EPS
The PS motor is controlled in response to handle operation via the steering torque sensor, tire position
via the tire angle sensor, and traveling speed pulses from the main controller.
Sensor / Switch Input Output Actuator
1 Accelerator sensor 15 Drive motor *1
2 Brake limit switch 16 Pump motor *2
3 Material handling lever switch (rear) [Multifunction display DX]
4 Material handling lever switch (front) 19 Main controller Speed meter
Battery capacity indicator
5 Reach limit switch Power select indicator
6 Tilt limit switch 12 Diagnostic code display
Diagnostic mode indicator
7 Attachment lever switch
8 Speed sensor (drive motor) *1 Low speed setting indicator
9 Temperature sensor (drive motor) *1 Onboard buzzer
10 Speed sensor (pump motor) *2
11 Temperature sensor (pump motor) *2
[Multifunction display DX]
12 Low speed setting switch
Power select switch
13 Steering torque sensor 17 Lift lock valve

controller
20 EPS
14 Tire angle sensor 18 PS motor
*1 Input and output for the drive motors for the speed sensor (drive motor) and temperature sensor (drive motor)
are via the drive AC driver.
*2 Input and output for the pump motors for the speed sensor (pump motor) and temperature sensor (pump motor)
are via the pump AC driver.
Lifting height switch
Load sensor
Steering torque sensor
Speed sensor (drive motor)
Tire angle sensor Front speed sensor

19-3
COMPONENTS
SPEED SENSOR (DRIVE MOTOR)
1401
27 NMF
9 14 0
2
1
13 14
21 11
8
20 2
23
22 6
24 14 3
3 28 1812 25 Speed sensor (drive motor)
4
7 15
5
Speed sensor (drive motor)
17
16 6
1 19
14
7
4
26 5 10
8
9
STEERING TORQUE SENSOR
10
4505
11
12
13
14
15
16
17
18
Steering torque sensor
19
20
21
19-4
FRONT SPEED SENSOR, LOAD SENSOR

5702
Load
sensor
Front speed sensor
G42819ZZ001_
TIRE ANGLE SENSOR

5803
19-5
LIFTING HEIGHT SWITCH (FOR FV AND FSV MAST)

)
5803
NMF
0
1
2
3
4
5
6
7
8
LIFTING HEIGHT SWITCH (FOR V AND SV MAST)
9
5803
10
11
12
13
14
15
16
17
18
19
20
21
19-6
FOR REPAIR WORK

For the inspection of functional parts, see the TROUBLESHOOTING section.
See section 8 for the swing lock cylinder, and section 10 for the brake valve.
Understand their functions sufficiently before repairing the TBC and EPS.
1. Preparation for repair work
(1) Avoid washing the vehicle as much as possible; for cleaning, blow compressed air. If washing
with water is required, avoid water jet washing. Always blow compressed air to remove water
after washing.
(2) Prepare necessary tools, instrument (analog tester), SST 09230-13130-71 and SST 09230-
13900-71.
2. During repair work
(1) Do not turn the key switch to ON and OFF carelessly when wiring, such as sensors, is
disconnected. If the key switch is turned to ON in this state, the diagnosis function is activated
and error codes are stored in the controller. Error codes cannot be cleared and up to ten error
codes can be stored. Beyond ten, older error codes will be eliminated sequentially.
(2) Don't turn the key switch to ON with the vehicle jacked up.Turning the key switch to ON will
unlock the swing lock and cause the vehicle to tilt suddenly, leading to great danger.
(3) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(4) Tighten the set bolts of respective functional parts to the specified torque.
(5) Though sensors do not require adjustment upon installation, perform matching.
(6) The swing lock cylinder cannot be disassembled.
3. Emergency action
(1) If the swing lock cannot be unlocked due to some
trouble, it can be manually unlocked as an
Swing lock emergency action.
unlocking plug Loosen the illustrated plug of the swing lock cylinder
(by 1 or 2 turns).
Do not overloosen it.
Tighten it securely after the end of repair.
T = 0.08 to 0.1 N·m (0.8 to 1 kgf·cm)
[0.06 to 0.07 ft·lbf]
(2) If the mast cannot be lowered, even though so

operated, due to some trouble, it can be manually
lowered as an emergency action.
Loosen the lift lock unlocking bolt and operated the
lift lever in a downward direction. Do not operate
the reach lever.
After repair, be sure to retighten the lift lock
unlocking bolt.
Otherwise, the lift speed will become remarkably
Lift lock unlocking bolt slow.
19-7
MATCHING
Of the sensors used for the TBC and EPS, the signal voltage values of the tire angle and steering torque
sensors at the ends of counterclockwise turn and clockwise turn, tire straight travel position and no
steering torque state are stored in the EPS controller to be used as the bases for control. Therefore, if
maintenance or parts replacement related to these sensors is performed, matching (updating sensor
signal voltage values of the vehicle in the vehicle standard state) becomes necessary. Matching for each
speed sensor becomes necessary to correct the difference between speed sensors due to wear or
replacement of the load and drive tires. For tire wear while the vehicle is in service, automatic matching
is performed when the vehicle satisfies given conditions (vehicle standard state). Matching under the
vehicle standard state is needed, therefore, after tire replacement, etc.
Matching (excluding speed) for each corresponding item is possible by selecting [MAT] tab on the
service function screen.
Note:
To perform each matching, refer to “MATCHING” on page 4-45 in repair manual Pub. No. CE352.
Steering Speed
Sensors subject to matching Tire angle sensor
torque sensor *1
TIRE TIRE RIGHT TIRE LEFT STEERING SPEED
Screen display
CENTER END END CENTER DATA
Maintenance operation examples:
1. EPS controller
{ { { { {
replacement
2. Remove and install or
replace the tire angle { { {
sensor.
3. Steering torque
{
sensor replacement
4. Load tire replacement {
5. Drive tire replacement {
*1: Automatic matching is performed when the vehicle satisfies the given conditions (vehicle standard
state).
CAUTION FOR VEHICLE ALTERATION

• For alteration from a mast whose lifting height is less than 3,000 mm (118.1 in) to a mast whose lifting
height is 3,300 mm (129.9 in) or more, add a lifting height switch.
• For alteration from a mast whose lifting height is 3,300 mm (129.9 in) or more to a mast whose lifting
height is less than 3,000 mm (118.1 in), remove the lifting height switch.
Note:
When ordering a mast ASSY as a spare, it is necessary to check the necessity of sensors (lifting
height switch, mast harness and other TBC related parts) and order them at the same time.
19-8
TIRE ANGLE SENSOR

G42819DB002_
Removal Procedure
1 Set the tire in the neutral position. [Point 1]
3 Disconnect the PS motor connector.
4 Disconnect the tire angle sensor connector.
5 Remove the tire angle sensor. [Point 2]
Note:
Perform matching when the tire angle sensor is removed, installed or replaced.
19-9
Point Operations
[Point 1]
Removal:
Turn the steering wheel to the left from the tire straight
travel position so that the notch in the drive unit support
is aligned with the match mark given on the turn gear.
(The tire is steered approx. 10° to the right then.)
Match mark
G42809ZZ003_
[Point 2]
Removal:
Make match marks on the tire angle sensor gear and the
body.
Carefully prevent the gear from rotating after removal.
Installation:
Install the tire angle sensor.
Match
1. Bring the gear and ring gear into close contact after
marks G42819DA001_
aligning the match marks, and temporarily tighten the
set bolt.
2. Shift the tire angle sensor until gear play is observed,
and tighten the set bolt finally in that position.
3. Perform tire angle sensor matching.
<Reference>
If the tire angle sensor neutral position is unknown,
install according to the following procedure:
1. Use one tire angle sensor set bolt and temporarily
install the sensor. (The gear should be able to be
rotated.)
2. Reconnect the tire angle sensor connector.
3. Reconnect the battery plug and turn key switch ON.
G42804DA035_
4. Make match marks (aligning marks) on the gear and
body in the position where the “VRTRA” value on the
analyzer
[I/O STEERING 1/1] screen is 2.20 (V).
5. Install the tire angle sensor according to the normal
procedure.
G42819DA002_
19-10
LOAD SENSOR
4
T = 22 to 26
(224 to 265)
[16 to 19]
Removal Procedure
1 Fully lower the fork.
3 Disconnect the wiring of the load sensor.
4 Remove the load sensor.
19-11
FRONT SPEED SENSOR

Sensor cover
1
T = 15 to 33 (150 to 330) [11 to 24]
3
Sensor bracket
T = 15 to 33 (150 to 330) [11 to 24]
T = 3 to 7 (31 to 71) [2.2 to 5.1]
Removal Procedure
1 Remove the front speed sensor W/bracket.
2 Disconnect the speed sensor connector.
3 Remove the front speed sensor. [Point 1]
Point Operations
[Point 1]
Installation:
Install the rubber cap so as to eliminate the clearance
between the sensor end and the cap.
Adjust the clearance between the load wheel and the
sensor by the sensor bracket position.
Rubber Standard: Clearance A 0.5 to 2.5 mm
cap
(0.02 to 0.10 in)
Run the sensor wiring around the outside of the bracket
pin.
19-12
SPEED SENSOR (DRIVE MOTOR)

3
2 1
2
T = 3 to 7 (31 to 71) [2.2 to 5.1]
T = 3 to 7 (31 to 71) [2.2 to 5.1]
G42819DB001_
Removal Procedure
1 Disconnect the wiring connectors.
2 Remove the speed sensor (drive motor) set bolts.
3 Remove the speed sensors (drive motor).
19-13
LIFTING HEIGHT SWITCH

V•SV mast
3
FV•FSV mast
Removal Procedure
1 Remove the lower cover.
2 Disconnect the wiring connector.
3 Remove the lifting height switch.
19-14
V•SV mast
5 4
2 3
FV•FSV mast
1
4 2
5
19-15
1. Remove the roller.
2. Remove the cover and gasket.
3. Remove the shaft, cam, return spring and bushing.
4. Remove the microswitch. [Point 1]
5. Remove the dust seal. [Point 2]
Note:
• Apply loctite 271 or similar on the roller set nut, cover set screw (FV•FSV mast only) and the
microswitch set screw threaded portion before reassembly.
• Apply esso beacon 325 or similar on the bushing inside surface and dust seal lip portion
before reassembly.
Point Operations
Inspection:
Inspect the microswitch for continuity.
Standard
Measurement
Push Release
terminals
COM - NO Continuity ∞ Ω
COM NO NC
COM - NC ∞ Ω Continuity
Reassembly:
SST (2)
Use the SST to install the dust seal.
SST 09950-76018-71 (09950-60010) ....(1)
SST (1) 09950-76020-71 (09950-70010) ....(2)
19-16
STEERING TORQUE SENSOR

To remove the main shaft W/steering torque sensor, refer to “STEERING SHAFT ASSY” on page 9-7.
Cam
3
2 Steering torque sensor
Installation direction sensor

1
1. Remove the steering torque sensor.
2. Remove the snap ring and cam.
3. Remove the cushion.
Note:
• Apply esso beacon 325 or similar on the camshaft portion before reassembly.
• Install the steering torque sensor and cam in the illustrated directions.
20E_APPENDIX.book 1 ページ２０１２年７月１０日火曜日午後３時４７分
20-1
APPENDIX
Page
SST LIST .................................................................20-2 0
SERVICE STANDARDS..........................................20-6 0
TERMINAL NUMBER .............................................20-11 1
CONNECTING DIAGRAM ......................................20-12
2
WIRING DIAGRAM .................................................20-13
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
20-2
SST LIST
21
Section
Illust. Part No. Part Name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
09090-76001-71 Engine sling


(09090-04020) device
09308-76001-71
Oil seal puller 
(09308-00010)
09718-76001-71 Brake shoe return


(09718-20010) spring replacer
09950-76014-71
Puller B set    
(09950-40011)
09950-76018-71
Replacer set  
(09950-60010)
09950-76019-71
Replacer set No.2  
(09950-60020)
09950-76020-71
Handle set   
(09950-70010)
Engine unit
09010-20111-71 
hanger
Counter shaft
09110-30200-71 remover & 
replacer
20-3
Section
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
09140-13130-71 AC/DC tester 
NMF
0
AC controller diag-
09230-13130-71
nosis kit

1
2
3
09230-13700-71 IC check pin 
4
5
09230-13900-71
AC controller
diagnosis kit
 6
7
8
Reamer bolt
09310-23320-71 
remover
9
10
09330-13900-71 Motor hook 
11
12
13
09340-13900-71 Adapter 
14
15
16
09480-13900-71 Push remover 
17
18
19
20
21
20-4
Section
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Brake hold-down
09510-31960-71 spring remover & 
replacer
Oil control valve

09610-10161-71 spring remover & 
replacer
09610-22000-71 Inner mast stopper  
Cylinder cap
09620-10100-71 
remover & replacer
09631-22000-71 Wear scale chain 
Spring pin tool

09700-30200-71    
remover
25009-13201-71 Battery hanger 

20-5
BRAKEDOWN OF SST
09230-13130-71
Illust. Part No. Part Name Use
09230-13130-71
AC controller NMF
diagnosis kit
0
1
(09232-13130-71) Short harness For A14, A15, A16, A17, A19, A32, B1 and S1
2
3
09230-13900-71 4
Illust. Part No. Part Name Use
5
09230-13900-71
AC controller
diagnosis kit
6
7
8
(09234-13900-71) Short harness For A33, A36
9
10
Sub-harness
(09236-13900-71) for front For H1, H2 11
speed sensor
12
Sub-harness
13
(09237-13900-71) for front For HA1, HA2
speed sensor 14
15
Sub-harness
(09238-13900-71) for load For A22 16
sensor
17
18
19
20
21
20-6
SERVICE STANDARDS
BATTERY
ITEM
Specific gravity upon full charge (at 20 °C (68 °F)) 1.280
Specific gravity upon end of discharge (at 20 °C (68 °F)) 1.150
Voltage upon end of discharge V 42.5
Insulation resistance MΩ 1 or more
CHARGER
ITEM
Magnet switch
FW-0S 1300
Magnet switch
FW-0 1300
coil resistance Ω
FW-1S 500
Thermal relay contact When not operated 0
continuity Ω When operated ∞
Transformer ASSY
Insulation resistance MΩ 1 or more
TR4225E 40
Fuse A/250 V TR4312E 50
TR4370E 60
Primary coil continuity Ω 0
Secondary coil continuity Ω 0
Forward Continuity
Diode continuity Ω
Backward ∞
Diode tightening torque N·m (kfg·cm) [ft·lbf] 2.6 ± 0.2 (26.5 ± 2) [1.9 ± 0.14]
TR4225E 74/78
No-load secondary voltage (50/60 Hz) V TR4312E 76/80
TR4370E 71/74.5
CONTROLLER
ITEM
F1 fuse (fuse for traveling and 1.0 to 1.3 ton 360
load handling circuits) A 1.5 to 1.8 ton 410
Between base and P1
Between base and P4
Between base and A32-1
Between base and A32-4
Contactor panel insulation resistance DC 500 V applied 10 MΩ more
Between P1 and A32-1
Tightening torque N·m (kgf·cm) [ft·lbf]
Drive or pump AC driver set bolt 5.5 (56.1) [4.1]
20-7
BRAKE LIMIT SWITCH

Brake limit switch ON dimension See page 11-12.
DRIVE MOTOR
ITEM
Clearance between speed sensor (drive motor) and 0.26 to 1.32
Standard
pickup gear mm (in) (0.01 to 0.05)
PUMP MOTOR
ITEM
Clearance between speed sensor (pump motor) and 0.26 to 1.32
Standard
pickup gear mm (in) (0.01 to 0.05)
POWER STEERING MOTOR

ITEM
Commutator outside diameter mm (in) Standard 33 (1.30)
Limit 31.5 (1.24)
Undercut mm (in) Standard 0.8 (0.031)
Limit 0.3 (0.012)
Commutator runout mm (in) Limit 0.05 (0.00197)
Armature coil insulation resistance MΩ Standard 1 or more
Brush length mm (in) Standard 20 (0.79)
Limit 11 (0.43)
Brush spring force N (kgf) [lbf] Standard 1.76 to 5.59 (0.18 to 0.57) [3.88 to 1.26]
Insulation resistance between
Standard 1 or more
brush holder and bracket MΩ
DRIVE UNIT
ITEM
Rotation bearing starting torque
30 to 52 (3.1 to 5.3) [6.7 to 11.7]/142 (5.59)
(Measure drive unit set nut) N (kgf) [lbf]/mm (in)
Drive unit starting torque
3.0 (0.31) [0.7]/200 (7.87)
(Measure coupling portion) N (kgf) [lbf]/mm (in)
Backlash between drive pinion and
0.13 to 0.18 (0.005 to 0.007)
ring gear mm (in)
Drive pinion bearing starting force
18 to 22 (1.84 to 2.24) [4.05 to 4.93]
(Measure retainer flange bolt hole) N (kgf) [lbf]
Turn gear 34 to 50 (347 to 510) [25.1 to 36.9]
Gear case cover 76 to 114 (775 to 1162) [56.1 to 84.1]
Gear case side cover 20 to 30 (204 to 306) [14.8 to 22.1]
Drive wheel bolt 118 to 166 (1203 to 1693) [87 to 122]
SUSPENTION
ITEM
New tire 9.5 to 10.5 (0.37 to 0.41)
Suspension bolt play mm (in) Standard
Adjustment 1.5 to 2.5 (0.06 to 0.10)
Caster tire for wear
Standard A = 120 (4.72)
(Min: outsidediameter) mm (in)
20-8
FRONT AXLE
ITEM
Load wheel looseness in axial
Standard 0.2 (0.0079) or less
direction mm (in)
Lock nut Standard 145 to 190 (1479 to 1937) [107 to 140]
STEERING
Tightening torque Unit: N·m (kgf·cm) [ft·lbf]
Steering wheel plate set bolt Standard 21 to 31 (215 to 315) [15.6 to 22.8]
Steering wheel knob set nut Standard 11 to 15 (110 to 155) [8.0 to 11.2]
FRONT BRAKE
ITEM
Shoe hold spring length mm (in) Standard 15.1 (0.594)
Shoe return spring Upper 86.3 (3.398)
Standard
free length mm (in) Lower 91.6 (3.606)
Standard 3.5 (0.138)
Brake lining thickness mm (in)
Limit 1.0 (0.039)
Standard 140 (5.51)
Load wheel inside diameter mm (in)
Limit 141 (5.55)
20 (0.787) (Rubber)
Load tire wear limit mm (in)
10 (0.393) (Urethane)
REAR BRAKE
ITEM
Brake pedal height mm (in) Standard 60 to 70 (2.36 to 2.75)
Disc wheel run out mm (in) Limit 0.1 (0.004)
Standard 10 (0.39)
Disc wheel thickness mm (in)
Limit 9 (0.35)
Standard 9 (0.35)
Brake pad thickness mm (in)
Wear limit 3 (0.12)
Clearance between brake pad
Standard 0.2 (0.01)
and disc wheel mm (in)
7FBR10·13 122 to 126 (4.80 to 4.96)
Brake spring installed length mm (in) 7FBR15 118 to 122 (4.65 to 4.80)
7FBR18 114 to 118 (4.49 to 4.65)
Brake spring free length mm (in) Standard 150 (5.91)

Natural drop test
Natural drop test mm (in) Limit 45 (1.77)
Oil leak test
Lift cylinder oil leak amount cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount
Standard 18 (1.10) or less
(Total for lift and tilt) cm3 (in3)
20-9
MAST
Mast adjustment (V mast)
Mast Inner mast roller clearance mm (in) Standard 0 to 0.5 (0 to 0.017)
rollers Outer mast roller clearance mm (in) Standard 0 to 0.5 (0 to 0.017)
Lift Middle and lower lift roller
0 to 0.5 (0 to 0.017)
bracket clearance mm (in)
rollers Side roller clearance mm (in) 0 to 0.5 (0 to 0.017)
Mast strip to inner mast clearance mm (in) Standard 0 to 0.8 (0 to 0.031)
Mast carriage roller clearance mm (in) Standard 0 to 0.5 (0 to 0.02)
Mast carriage side roller clearance mm (in) Standard 0 to 0.5 (0 to 0.02)
Fork
Fork front end misalignment mm (in) Limit 10 (00.39)
Chain adjusting nut Standard 50.0 to 78.0 (500 to 800) [36.2 to 57.9]
CYLINDER
Lift cylinder (V, SV) / Rear lift cylinder (FSV)
Piston rod outside diameter mm (in) Limit 34.92 (1.3748)
Cylinder bore mm (in) Limit 45.20 (1.7795)
Rear lift cylinder (FV)
Front lift cylinder (FV·FSV)
Reach cylinder
Piston rod bend mm (in) Limit 2.0 (0.079)
Tilt cylinder
V Limit 50.35 (1.9823)
Cylinder bore mm (in)
SV·FV·FSV Limit 55.35 (2.1791)
Piston rod bent mm (in) Limit 0.5 (0.02)
58.8 to 68.9 (600 to 700)
Flow regulator valve Standard
[43.4 to 50.6]
53.9 to 68.6 (550 to 700)
Safety down valve Standard
[39.8 to 50.6]
OIL PUMP
Oil pump ASSY
Side plate thickness mm (in) Limit 0.15 (0.006) or less at LBC surface
Gear shaft outside diameter mm (in) Limit 21.997 (0.87)
Gear face width mm (in) Limit 19.3 (0.76)
20-10
OIL CONTROL VALVE

Oil control valve
Relief set pressure 7FBR10·13 Standard 12.2 (125) [1780]
MPa (kgf/cm ) [psi] 7FBR15·18
2
Standard 16.8 (170) [2420]
HYDRAULIC PIPING
Oil tank cover set bolt Standard 6 to 10 (61.2 to 102.0) [4.43 to 7.38]
EPS, TBC
Load sensor Standard 22 to 26 (224 to 265) [16 to 19]
Front speed sensor set bolt Standard 3.0 to 7.0 (31 to 71) [2.2 to 5.1]
Speed sensor (drive motor) set bolt Standard 3.0 to 7.0 (31 to 71) [2.2 to 5.1]
20-11
TERMINAL NUMBER
1.0 ~ 1.3t 1.5 ~ 1.8t

F1 360A (MAX) 410A (MAX)
F6 10A (MAX) 10A (MAX)
F7 10A (MAX) 10A (MAX)
L3 K1  
[P1] MB [P2]
J5 [W(P9)] I5 [W(P16)]
J3 [V(P8)] I3 [V(P15)]
F1
F F A28 A29
6 7 J1 [U(P7)] [CN110] I1 [U(P14)] [CN111]
A32
[CN135] R1 [P4]
+ ACMDD + ACMDP
A27 [CN104]
A26 [CN103] DC/DC CONT
A25 [CN102]
A33 [CN138]
A24 [CN101]
MAIN CONT
BTS/PS
A34 A13 A35 A36 A37
[CN140] [CN51] [CN141] [CN142] [CN143]
57873-13900-71-A
G42820TA002_
20-12
CONNECTING DIAGRAM
Z23 D2
LR
AD1-6 [CN13-6]
LF-L LH-L
Cold storage vehicle LW LLM

AD1-2 [CN13-2]
AD1-3 [CN13-3]
D4 D5 D6 Z24 D1
[CN18] V1
AD2-4 [CN17-4]
AD2-2 [CN17-2]
LSL [CN306] SWH
S MG N
Z26 LF-R
SWLM2
Z10 [CN L] SWL SWF C4 C5 LH-R
[CN30]
LSR V2 [CN307]
Z11 [CN R] UV1
[CN305] C1 C3 SWK D3
MAST [CN3] [CN8] D1 D2
LST C2 [CN4] [CN14]
AD1-4 [CN13-4]
AD1-5 [CN13-5]
Z12 [CN T]
FR
AE1 WU1 Z8
TEN KEY
<OPT>
Z9 ACC
[CN11] Z7 [CN31] [CN301] [CN73]
[CN74]
RR B1
M1 DISP LSAT2 E2 ATT1 [CN26]
Cold storage vehicle SWLM1
Z25 [CN29] [CN33] M3 [CN72]
TW1 [CN70] E1
T1 AC1
[CN300] LST [CN71] B2
AG1 [CN6] [CN304] [CN69] LSR SOLL
C6 [CN27]
LSB AM1 AB1
SA
[CN1] AE1 [CN25] AD1
A42 [CN28]
Z7-3 [CN31-3], Z26-1 [CN30-1]
AC1-3[CN69-3]
AT1 C7 [CN11] [CN13]
AF1 [CN39]
LSL2 [CN220]
Z7-2 [CN31-2]
A18
AD2 [CN17] [CN86]
F3 SPL
A10 [CN44]
A22[CN91]
LSL2
LSL
LSBATT
LSB A27 [CN104]
QP1 PA1 AG1 AF1
FORWARD/REVESE A24 [CN101] AN1[CN36] N1[CN35]
[CN93] [CN90] [CN6] [CN39] A26 [CN103]
CHIME A7 [CN24(F)] Z15 Z16 A25 [CN102] SLL
PBMAIN
A4
SWMH AC1-3[CN69-3]
A32[CN135] L1
LSBATT A34 [CN140] PBBTS PBDC/DC
H A11 A13 [CN51] A36 [CN142] A33
Q1 LBU A35 [CN141] A37 [CN143] [CN138] BATT
[CN47]
CHI-F&R [CN92] A5 A7 DIAG
[CN24(F)] A10[CN44]
Z25-2 [CN29-2]
L3
Z25-1 [CN29-1]
A6 [CN23(R)] Case A19

FORM LIGHT
CHI-F AX1 [CN87]
K1
Z25-2 [CN29-2]
*2 ADJUSTABLE [CN20]
*2 A12 A28 A30
VOL. BZ SPIRAL R1
[CN50] [CN113]
MB
A29 [CN111] [CN110]
A39 A40 LSPA
Z13 Z14 [CN42] Z18
Z17 [CN232] [CN233] SSFR
[CN41] Z22 BZ-R A6
Z21
Cooling fan
Z19 Z20 [CN23(R)] SST
DMPS
X1
A6 LSP LS FRY
ACMDP
ACMDD
SWS [CN19] PW W
[CN23(R)] J5 I5
A1 H1
PV V
[CN12] AC power plug J3 I3 SOLBC SOLBS [CN83]
SSFL PU U
J1 I1
MSCH N L2 N1
M2
VRAH [CN68] A20 [CN88]
ACMD
STDM
H2 ACMP
STPM
F4
[CN84] F5 SW BOX U U
A2 J2 I2 S1 [CN53]
V A17 V
A21 [CN89]
[CN16] J4 I4 SSD2
A8
W SSP [CN56] W
[CN32] SOLS A23 K2 A15[CN54]
TF J6 I6 SSD1
[CN95]
A14 A9 LSD
Z1 [CN61] A16 [CN52] [CN43]
AS1
[CN55]
[CN49]
HA2
[CN82]
HA1 [CN81]
G42820DA003_
20-13
WIRING DIAGRAM
to PBCPU
*2
to PS
*1
to PBBTS
to PBBTS
to PBBTS
to PBBTS to PBBTS
to PBBTS to PBBTS
to PBBTS Pin code entry (OPT)
*2
CH CHARGER PBMAIN MAIN CONTROLLER LSB BRAKE LIMIT SWITCH
*1
TF TRANSFORMER ASSY PBDC/DC DC/DC CONTROLLER LSPA PRESURE SWITCH
MSCH CHARGER MAGNET SWITCH PBBTS PS CONTROLLER LST TILT LIMIT SWITCH
THR THERMAL RELAY ACMDD DRIVE AC DRIVER LSBATT BATTERY SWITCH
DCH CHARGER DIODE ACMDP MATERIAL HANDLING AC DRIVER LSD FLOOR SWITCH
FCH CHARGER FUSE SWK KEY SWITCH
Case FORM LIGHT
TMPS1 MAIN TRANSISTOR POWER STEERING NO.1 SWL LIGHTING SWITCH
BATT BATTERY TMPS2 MAIN TRANSISTOR POWER STEERING NO.2 SWF TURN SIGNAL SWITCH
F1 FUSE, DRIVE TMPS3 MAIN TRANSISTOR POWER STEERING NO.3 SWH HORE SWITCH
F3 FUSE, POWER STEERING TMPS4 MAIN TRANSISTOR POWER STEERING NO.4 SWMH LIFTING HEIGHT SWITCH
F4 FUSE, LAMP SH1 POWER STEERING SHANT SW SEARCH LIGHT SWITCH
F5 FUSE, CONTROL CIRCUIT SH2 POWER STEERING SHANT SWLM1 LASER MARKER SWITCH
F6 FUSE, BTS/PS & SOLENOID SWLM2 LASER LAMP SWITCH
F7 FUSE, PB BTS SPL LOAD SENSOR LH-L HEAD LAMP LH
DISP MULTIFUNCTION DISPLAY DX SSD SPEED SENSOR (DRIVE MOTOR) LH-R HEAD LAMP RH FORWARD/REVESE
DIAG DIAGNOSIS CONNECTOR SSP SPEED SENSOR (PUMP MOTOR) LF-L TURN SIGNAL LAMP (LH) CHIME
TEN KEY TEN-KEY STDM TEMPERATURE SENSOR (DRIVE MOTOR) LF-R TURN SIGNAL LAMP (RH)
BOXCHG CHARGER BOX STPM TEMPERATURE SENSOR (PUMP MOTOR) LWS WORKINGLAMP
ADJUSTABLE VOL. BZ
ACMD DRIVE MOTOR SSFL FRONT SPEED SENSOR (LEFT) LS SEARCH LAMP
ACMP PUMP MOTOR SSFR FRONT SPEED SENSOR (RIGHT) LR ROTALY LAMP
DMPS POWER STEERING MOTOR SST STEERING TORQUE SENSOR LBU BACK-UP LAMP
SLL BATTERY ELECTROLYTE LEVEL / TEMPERATURE SENSOR LSP SPOT LIGHT LAMP
SOLBC BRAKE PROPORTIONAL SOLENOID MB BATTERY CONTACTOR LLM LASER MARKER LAMP
SOLBS BRAKE CUT-OFF SOLENOID MPS POWER STEERING CONTACTOR BZ-R BUZZER REVERSE
SOLL LIFT LOCK SOLENOID CHIF FORWARD CHIME
SOLS SWING SOLENOID DSFO FORWARD OPTIONAL DIRECTION SWITCH CHIR REVERSE CHIME
FAN FAN DSBU BACK-UP DIRECTION SWITCH H HORN
LSL MATERIAL HANDLING LEVER SWITCH (FRONT) FRY FLASHER RELAY
VRAD DRIVE ACCEL VARI-OHM LSL2 MATERIAL HANDLING LEVER SWITCH (REAR) SA SURGE ABSORBER
LSATT1 ATTACHMENT 1 LIMIT SWITCH
VRAH TIRE VARI-OHM(HANDLE) LSATT2 ATTACHMENT 2 LIMIT SWITCH
LSR REACH LIMIT SWITCH G42820DA002_
copyright_E_vol1.fm 1 ページ２０１２年７月９日月曜日午前７時２６分
Published by
1st Printing: July 2012
Pub. No. CE351
Printed in Japan
DA

7FBR RM Vol1 CE351

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foreword_E_vol1.

fm 1 ページ ２０１２年７月９日 月曜日 午前７時２７分

For electrical wiring diagrams, diagnosis and service procedures of electrical

TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18

INSTRUCTION MANUAL NMF

NEW MODEL FEATURES

MAIN SELLING POINTS

z: Newly adopted item {: Improved item

 Change in vehicle body color

MAIN DIFFERENCES FROM PREVIOUS MODELS

Useful life y (300 times/year)

Electrolyte temperature °C Degree of discharge %

 Control block diagram

Output signal cable

Current sensor Main controller

Electrolyte level sensor

 Name and feature of each component

Electrolyte level warning LED (red) lingts up. G428ZZ136_

2. Battery electrolyte level sensing vehicle performance limit

Battery electrolyte level sensing

Total time of use under electrolyte level warning conditions [h]

Battery electrolyte sensing vehicle performance limit indicator

3. Battery electrolyte temperature warning

Battery overheat warning LED indicator (red) lights up.

4. Battery electrolyte temperature sensing vehicle performance limit

Battery electrolyte temperature

Adjustable up to 77 °C using the service

(2) Daily integrated power/CO2 emissions display

(3) CO2 unit setting

(4) Reset of the integrated power data

 Comparative table for effective operating times

 List of continuous operating time for each charging (S mode)

R300 type Battery replacement specification

Battery list (manufacturer: GS YUASA)

R300 type Battery replacement specification

Battery model list

Battery capacity Single battery Battery case Model

 External charger list (manufacturer: GS YUASA)

Charging progress indicator

(Fig.01) Charging completion time

 Description of operation panel

EQUAL LED (yellow)

UP LED (green) NORMAL LED (yellow)

STOP switch START switch

(1) EQUAL LED (yellow)

Switch (1) Switch (2) Switch (3) Switch (4)

(1) Switch (1)

Initial screen Start screen

(Fig.05) G428ZZ275_ (Fig.06) G428ZZ276_

(2) Routine charge (normal charge)

(3) Manual equalizing charge

(4) Completion of charge

If a power interruption occurs during charging,

(5) Stop of charge

Confirm from the menu on the initial screen (Fig.17,18)

Switch (1) Switch (4)

Confirm during charging (Fig.19)

"What is charge count"

Field core Terminal block

Rotor Field coil

Rotor Field coil

ELECTRICAL CONTROLLER SYSTEM

Drive Motor Pump Motor PS Motor

fm 1 ページ２０１２年７月９日月曜日午前７時２７分

Change in vehicle body color

Control block diagram

Name and feature of each component

Comparative table for effective operating times

List of continuous operating time for each charging (S mode)

External charger list (manufacturer: GS YUASA)

Description of operation panel

Structure and feature of each component

Load handling function

Power steering function

Power select function

Remaining battery charge calculating function

Key on return-to-neutral function